Skip to main content
SpringerLink
Log in

Tri-dexel-based cutter-workpiece engagement: computation and validation for virtual machining operations

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In the Industry 4.0 era, the modelling of machining operations happens to be a crucial aspect of production sector. With adequate models, predicting the appearance of chatter and selecting optimised operational parameters is possible. 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 cutter-workpiece engagement (CWE) computation at each step of a dynamic simulation, by determining the machining forces as well as 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 surface of the swept volume. The relative closest triangle algorithm is used for a robust intersection management, suited for 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. It allows to assess the impact of operational parameters on parts at the simulation level. The CWE determination method proposed is validated with experimental data from force measurements and benchmark tests of different scales from macro- to micro-milling.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Availability of data and materials

Not applicable.

Code availability

Soon released.

References

  1. Arrazola PJ, Özel T, Umbrello D, Davies M, Jawahir IS (2013) Recent advances in modelling of metal machining processes. CIRP Ann 62(2):695–718. https://doi.org/10.1016/j.cirp.2013.05.006

    Article  Google Scholar 

  2. Altintas Y, Kersting P, Biermann D, Budak E, Denkena B, Lazoglu I (2014) Virtual process systems for part machining operations. CIRP Ann Manuf Technol 63

  3. Peigné G, Brissaud D (2003) A model of milled surface generation for time domain simulation of high-speed cutting. In: Proceedings of the institution of mechanical engineers part b-journal of engineering manufacture, vol 217, pp 919–930

  4. Huynh HN, Rivière-Lorphèvre E, Ducobu F, Ozcan A, Verlinden O (2018) Dystamill: a framework dedicated to the dynamic simulation of milling operations for stability assessment. Int J Adv Manufact Technol 98(5):2109–2126

    Article  Google Scholar 

  5. Surmann T, Enk D (2007) Simulation of milling tool vibration trajectories along changing engagement conditions. Int J Machine Tools & Manufact 47:1442–1448

    Article  Google Scholar 

  6. Boz Y, Erdim H, Lazoglu I (2015) A comparison of solid model and three-orthogonal dexelfield methods for cutter-workpiece engagement calculations in three- and five-axis virtual milling. Int J Adv Manufact Technol 81

  7. Joy J, Feng H-Y (2017) Frame-sliced voxel representation: an accurate and memory-efficient modeling method for workpiece geometry in machining simulation. Comput Aided Des 88

  8. Schnoes F, Zaeh MF (2019) Model-based planning of machining operations for industrial robots. Procedia CIRP 82:497–502

    Article  Google Scholar 

  9. Inui M, Kobayashi M, Umezu N (2019) Cutter engagement feature extraction using triple-dexel representation workpiece model and GPU parallel processing function. Computer-Aided Design Appl 16:89–102

    Article  Google Scholar 

  10. Denkena B, Grove T, Pape O (2019) Optimization of complex cutting tools using a multi-dexel based material removal simulation. Procedia CIRP 82:379–382

    Article  Google Scholar 

  11. Denkena B, Kroedel A, Pape O, Muecke A, Ellersiek L (2021) Identification of rake and flank face engagement parameters using a dexel-based material removal simulation with an oriented sweep volume. CIRP J Manuf Sci Technol 35:146–157

    Article  Google Scholar 

  12. Magalhães SVG, Andrade MVA, Franklin WR, Li W (2016) PinMesh—fast and exact 3D point location queries using a uniform grid. Comput Graph 58:1–11. Shape modeling international

    Article  Google Scholar 

  13. Liu J, Chen YQ, Maisog JM, Luta G (2010) A new point containment test algorithm based on preprocessing and determining triangles. Comput Aided Des 42(12):1143–1150

    Article  Google Scholar 

  14. Denkena B, Pape O, Kroedel A, Böß V, Ellersiek L, Muecke A (2020) Process design for 5-axis ball end milling using a real-time capable dynamic material removal simulation. Production Engineering 15

  15. Böß V, Ammermann C, Niederwestberg D, Denkena B (2012) Contact zone analysis based on multidexel workpiece model and detailed tool geometry representation. Procedia CIRP 4:41–45

    Article  Google Scholar 

  16. Bauer J, Friedmann M, Hemker T, Pischan M, Reinl C, Abele E, Von Stryk O (2013) Analysis of industrial robot structure and milling process interaction for path manipulation. Process Machine Interactions 245–263

  17. Sun Y, Yan C, Wu S-W, Gong H, Lee C-H (2018) Geometric simulation of 5-axis hybrid additive-subtractive manufacturing based on tri-dexel model. The International Journal of Advanced Manufacturing Technology 99

  18. Luo S, Dong Z, Jun M (2017) Chip volume and cutting force calculations in 5-axis CNC machining of free-form surfaces using flat-end mills. The International Journal of Advanced Manufacturing Technology 90

  19. Verl A, Valente A, Melkote S, Brecher C, Ozturk E, Tunc T (2019) Robots in machining. CIRP Ann 799–822

  20. Rivière-Lorphèvre E, Hoai Nam H, Verlinden O (2018) Influence of the time step selection on dynamic simulation of milling operation. Int J Adv Manufact Technol 95:1–16

    Article  Google Scholar 

  21. Sullivan CB, Kaszynski A (2019) PyVista: 3D plotting and mesh analysis through a streamlined interface for the Visualization Toolkit (VTK). Journal of Open Source Software 4(37):1450

    Article  ADS  Google Scholar 

  22. Peukert BW, Archenti A (2021) A modular node-based modeling platform for the simulation of machining processes. euspen’s 21st International Conference & Exhibition, Copenhagen 351–354

  23. Altintas Y, Engin S (2001) Generalized modeling of mechanics and dynamics of milling cutters. Cirp Annals-manufacturing Technology - CIRP Ann-Manuf Technol 50:25–30

    Article  Google Scholar 

  24. Dambly V, Rivière-Lorphèvre E, Verlinden O (2022) Tri-dexel based cutter-workpiece engagement determination for robotic machining simulator. Proceedings of the 55th CIRP Conference on Manufacturing Systems 2022, vol 107, pp 1059–1064

  25. Engin S, Altintas Y (2001) Mechanics and dynamics of general milling cutters. Part I: helical end mills. Int J Mach Tools Manuf 41:2195–2212

    Article  Google Scholar 

  26. Rivière-Lorphèvre E, Letot C, Ducobu F, Dehombreux P, Filippi E (2016) Dynamic simulation of milling operations with small diameter milling cutters: effect of material heterogeneity on the cutting force model. Meccanica 52

  27. Huynh HN, Assadi H, Dambly V, Rivière-Lorphèvre E, Verlinden O (2021) Direct method for updating flexible multibody systems applied to a milling robot. Robot Comput Integr Manuf 68

Download references

Acknowledgements

The authors would like to acknowledge the Belgian National Fund for Scientific Research (FNRS-FRS) for the grant allotted to V. Dambly.

Funding

This work was supported by the Belgian National Fund for Scientific Research (FNRS-FRS) under the grant number 5107620F.

Author information

Author notes

  1. Édouard Rivière-Lorphèvre, François Ducobu and Olivier Verlinden contributed equally to this work.

Authors and Affiliations

  1. Machine Design and Production Engineering Lab, Research Institute for Science and Material Engineering, UMONS, Place du Parc 20, Mons, 7000, Belgium

    Valentin Dambly, Édouard Rivière-Lorphèvre & François Ducobu

  2. Theoretical Mechanics, Dynamics and Vibrations Lab, Research Institute for Science and Material Engineering, UMONS, Place du Parc 20, Mons, 7000, Belgium

    Valentin Dambly & Olivier Verlinden

Authors
  1. Valentin Dambly
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Édouard Rivière-Lorphèvre
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. François Ducobu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Olivier Verlinden
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

CRediT: V. Dambly: conceptualisation, development, experimental, writing — original draft; É. Rivière-Lorphèvre: conceptualisation, experimental, supervision, writing — review and editing; O. Verlinden: conceptualisation, supervision, writing — review and editing; F. Ducobu: experimental, supervision, writing — review and editing.

Corresponding author

Correspondence to Valentin Dambly.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

The authors give their consent.

Consent for publication

Not applicable.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Dambly, V., Rivière-Lorphèvre, É., Ducobu, F. et al. Tri-dexel-based cutter-workpiece engagement: computation and validation for virtual machining operations. Int J Adv Manuf Technol 131, 623–635 (2024). https://doi.org/10.1007/s00170-023-10950-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-10950-z

Keywords

Search

Navigation