Modelling of cutter-workpiece engagement with tri-dexel approach for dynamic simulations

Abstract

Abstract In the context of Industry 4.0, the modelling of machining operations happens to be a crucial aspect of production sector. With adequate models, it is possible to predict the appearance of chatter and select optimised operational parameters. For the dynamics simulation of machine tools or robots performing 5-axis operations, modelling approaches are continuously in improvement. A robust method is proposed for the computation of the cutter-workpiece engagement (CWE) at each step of a dynamic simulation for the determination of the machining forces and the resulting machined surface. The CWE is estimated based on the interference between the workpiece, modelled with tri-dexel approach, and the tool, considered as a triangle-mesh swept volume. The relative-closest triangle algorithm is used for a robust intersection management with 5-axis trajectories. A hybrid dexel-based-analytic method is presented for accurate estimation of the uncut chip thickness. Furthermore, an approach is proposed for a simulation-based evaluation of the part resulting from dynamic simulations by comparing dexel networks with each other, allowing to assess the impact of operational parameters on the parts. The proposition is validated through experimental and virtual data with forces measurements as well as benchmark tests.