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Voxel-based modeling of transient material removal in machining

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Abstract

In the present study, a novel framework is presented that models the transient interaction between cutting teeth of an arbitrary end mill geometry and a workpiece. In this framework, the workpiece geometry is modeled using a voxelized representation that is dynamically updated as material is locally removed by each tooth of the cutting tool. A ray casting approach was used to mimic the process of the cutting faces of the tool intersecting the workpiece material. This ray casting approach was used to calculate the instantaneous undeformed chip thickness. The resulting voxel-based model framework was validated by comparison of predictions with experimentally measured milling forces. The effect of voxel size on model predictions was evaluated, and the ability of the model to describe the interactive effects of sequential machining passes was also investigated. Implications of this voxel-based model framework in terms of utility for predicting local surface finish and computational scalability of complex cutting configurations are briefly discussed.

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Availability of data and materials

All simulation data is available upon request to the corresponding author.

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Funding

This work was partially supported by NSF CMMI-1646013, CMMI-1825640, and IIP-1631803.

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Authors and Affiliations

  1. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332, USA

    John C. Miers, Thomas Kurfess & Christopher Saldana

  2. Tucker Innovations, Waxhaw, NC, 28173, USA

    Tommy Tucker

Authors
  1. John C. Miers
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  2. Tommy Tucker
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  3. Thomas Kurfess
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  4. Christopher Saldana
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Contributions

John Miers conducted the experiments and simulations, analyzed the results, and wrote the manuscript.

Thomas Tucker supported the analysis of results, as well as wrote and edited the manuscript.

Thomas Kurfess supported analysis of the results, as well as wrote and edited the manuscript.

Christopher Saldana conceived the study objectives, supported the analysis of results, as well as wrote and edited the manuscript.

Corresponding author

Correspondence to Christopher Saldana.

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The authors declare no competing interests.

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Miers, J.C., Tucker, T., Kurfess, T. et al. Voxel-based modeling of transient material removal in machining. Int J Adv Manuf Technol 116, 1575–1589 (2021). https://doi.org/10.1007/s00170-021-07545-x

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  • DOI: https://doi.org/10.1007/s00170-021-07545-x

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