High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory
Virtual simulation of high-resolution multi-axis machining processes nowadays plays an important role in the production of complex parts in various industries. In order to improve the surface quality and productivity, process parameters, such as spindle speed, feedrate, and depth of cut, need to be...
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MDPI AG
2025-01-01
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| Series: | Machines |
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| Online Access: | https://www.mdpi.com/2075-1702/13/1/69 |
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| author | Zhengwen Nie Yanzheng Zhao |
| author_facet | Zhengwen Nie Yanzheng Zhao |
| author_sort | Zhengwen Nie |
| collection | DOAJ |
| description | Virtual simulation of high-resolution multi-axis machining processes nowadays plays an important role in the production of complex parts in various industries. In order to improve the surface quality and productivity, process parameters, such as spindle speed, feedrate, and depth of cut, need to be optimized by using an accurate process model of milling, which requires both the fast virtual prototyping of machined part geometry for tool path verification and accurate determination of cutter–workpiece engagement for cutting force predictions. Under these circumstances, this paper presents an effective volumetric method that can accurately provide the required geometric information with high and stable computational efficiency under the condition of high grid resolution. The proposed method is built on a tri-level grid, which applies two levels of adaptive refinement in space decomposition to abolish the adverse effect of a large fine-level branching factor on its efficiency. Since hierarchical space decomposition is used, this multi-level representation enables the batch processing of affected voxels and minimal intersection calculations, achieving fast and accurate modeling results. To calculate the instantaneous engagement region, the immersion angles are obtained by fusing the intersection points between the bottom-level voxel edges and the cutter surface, which are then trimmed by feasible contact arcs determined using envelope theory. In a series of test cases, the proposed method shows higher efficiency than the tri-dexel model and stronger applicability in high-precision machining than the two-level grid. |
| format | Article |
| id | doaj-art-43fb549be2c540ab81d8b4f93d2ce991 |
| institution | Kabale University |
| issn | 2075-1702 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj-art-43fb549be2c540ab81d8b4f93d2ce9912025-01-24T13:39:21ZengMDPI AGMachines2075-17022025-01-011316910.3390/machines13010069High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope TheoryZhengwen Nie0Yanzheng Zhao1School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, ChinaSchool of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, ChinaVirtual simulation of high-resolution multi-axis machining processes nowadays plays an important role in the production of complex parts in various industries. In order to improve the surface quality and productivity, process parameters, such as spindle speed, feedrate, and depth of cut, need to be optimized by using an accurate process model of milling, which requires both the fast virtual prototyping of machined part geometry for tool path verification and accurate determination of cutter–workpiece engagement for cutting force predictions. Under these circumstances, this paper presents an effective volumetric method that can accurately provide the required geometric information with high and stable computational efficiency under the condition of high grid resolution. The proposed method is built on a tri-level grid, which applies two levels of adaptive refinement in space decomposition to abolish the adverse effect of a large fine-level branching factor on its efficiency. Since hierarchical space decomposition is used, this multi-level representation enables the batch processing of affected voxels and minimal intersection calculations, achieving fast and accurate modeling results. To calculate the instantaneous engagement region, the immersion angles are obtained by fusing the intersection points between the bottom-level voxel edges and the cutter surface, which are then trimmed by feasible contact arcs determined using envelope theory. In a series of test cases, the proposed method shows higher efficiency than the tri-dexel model and stronger applicability in high-precision machining than the two-level grid.https://www.mdpi.com/2075-1702/13/1/69accuracycomputer-aided manufacturingefficiencygrazing pointvirtual machining |
| spellingShingle | Zhengwen Nie Yanzheng Zhao High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory Machines accuracy computer-aided manufacturing efficiency grazing point virtual machining |
| title | High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory |
| title_full | High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory |
| title_fullStr | High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory |
| title_full_unstemmed | High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory |
| title_short | High-Accuracy and Efficient Simulation of Numerical Control Machining Using Tri-Level Grid and Envelope Theory |
| title_sort | high accuracy and efficient simulation of numerical control machining using tri level grid and envelope theory |
| topic | accuracy computer-aided manufacturing efficiency grazing point virtual machining |
| url | https://www.mdpi.com/2075-1702/13/1/69 |
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