High Speed Computational Algorithm in Voxel Based Milling Process Simulation for Minute Time and Minute Space Resolution Analysis

Abstract

In order to improve machining efficiency, it is required to recognize machining status and optimize cutting conditions. Cutting force is meaningful information to recognize machining status. In the instantaneous rigid force model, which is the most popular model for milling force prediction, milling force is calculated based on the geometrical intersection between cutting edge and workpiece for each feed per tooth. In this model, both of static tool deflection and tool dynamic vibration are not considered. In order to overcome this problem, a new high speed computational algorithm in our voxel based milling process simulation is proposed. The proposed algorithm permits to consider both of static tool deflection and tool dynamic vibration in our voxel based milling process simulation. In the proposed algorithm, the intersection between cutting edge and workpiece is calculated in each minute time interval or minute tool rotational angle interval. Furthermore, the proposed algorithm permits to shorten the computational time of detecting removal voxels to calculate uncut chip thickness discretely. Therefore, high precision analysis can be performed in minute space resolution. The effectiveness of the proposed algorithm is validated by experimental 3-axis milling tests. Predicted milling forces under several cutting conditions have good agreement with the measured milling forces.