A Cutting Simulation System for Machinability Evaluation Using a Workpiece Model

This paper describes a cutting simulation system to be used in the evaluation of machinability of products at various stages of the manufacturing processes. The system developed consists of geometric simulation and physical simulation. The geometric simulation is performed by using extended Z buffer models representing a workpiece and a tool swept volume. In the physical simulation, instantaneous cutting force vectors acting on a square end mill are computed based on the am of chip element removed by a thin divided section of a flute. The tool deflection induced by the cutting force is then calculated. The result is used to estimate the machining error caused by tool deflection. A series of cutting experiments are conducted to verify the effectiveness of the system.