Abstract
In this paper, we propose a new geometrical estimation method of sculptured workpiece surface for accurate cutting force prediction. In conventional methods of cutting force prediction, accurate representation of workpiece shape is required in order to calculate undeformed chip thickness at each tool position and tool rotation angle. However, workpiece in finish machining usually has complicated shape. So, it is difficult to realize workpiece shape estimation with sufficient accuracy in a short time. Then, we introduce an approximate model of instantaneous cutting force prediction and propose a new geometrical estimation method for undeformed chip thickness. At first, we introduce an estimation method of undeformed chip thickness based on the interference between sculptured workpiece and finite flutes on cutting edges. Then, we propose new concept of implicit representation for workpiece shape. It is based on the idea of tool swept volume. Next, we illustrate a new algorithm, which can realize effectively cutting force prediction. Finally, we developed a prototype system of cutting force prediction in order to evaluate the proposed methods. Then, we show the experimental results and conclusions.
