Realistic simulation of surface defects in five-axis milling using the measured geometry of the tool

Abstract

Managing macro and micro geometry of surfaces during manufacturing processes is a key factor for their following uses. Indeed micro-geometry and surface topography are directly linked to the performances of functions (contact, friction, lubrication, etc.) by texture parameters to ensure the desired local geometry. Common models for simulation of surface topography are based on ideal geometry of the machining tool and cannot represent surface defects. The actual prediction and simulation of defects is one step forward in a competitive context. In this paper, the realistic model proposed aims to simulate and predict as finely as possible local defects of machined surfaces taking into account the actual edge geometry of the cutting tool. The combined use of the machining kinematics and of the measured geometry of the cutting edges leads to the representation of the geometrical envelope of the surface using a Zbuffer technique. Simulation assessment is carried out by the analysis of 3D surface topography parameters such as surface complexity and relative area, and by a comparison of simulation results to an experimental case of study.

Evaluation and systematic selection of significant multi-scale surface roughness parameters (SRPs) as process monitoring index

“…(Wang et al, 2006) developed a mixed lubrication model for non-Gaussian rough surfaces and optimized the pattern by correcting grooves, skewness, area ratio, and load ratio. Along with experimental analysis, a theoretical model was developed by (Lavernhe et al, 2014) using multi-scale areal analysis for three axis ball-end milling for predicting tool path.…”

Performance evaluation of CUDA programming for 5-axis machining multi-scale simulation

“…If we consider the Z-buffer or N-buffer methods applied to a realistic description of both the tools and the machining path, earlier work have shown that it is possible to simulate the resulting geometry on small portions of the surface in a few minutes [8,9]. Simulation results are very close to experimental results but the simulated surfaces have an area of a few square millimeters with micrometer resolution (Fig.…”

Effective NC machining simulation with OptiX ray tracing engine

“…Some of them are based on partitioning the space whether by lines [6], by voxels [5] or by planes [11], other are based on meshes [3]. Previous works have shown that it is possible to simulate the resulting geometry of the surface with Z-or N-buffer methods applied to a realistic description of both the tools and the machining path in a few minutes [7]. Simulation results are very close to experimental results but the simulated surfaces have an area of some few square millimeters with micrometer resolution.…”