A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

[+] Author and Article Information
Jing Zhou

 University of British Columbia, 2324 Main Mall, Vancouver, BC, V6T 1Z4, Canadaevajzhou@mech.ubc.ca

Derek Yip-Hoi

 Western Washington University, 516 High Street, ET 313, Bellingham, WA 98225Derek.Yip-Hoi@wwu.edu

Xuemei Huang

 NRC–IMTI, 800 Collip Circle, London, ON, N6G 4X8, CanadaHuangXu@nrc.ca

An overview of the use of Green’s theorem for area calculations in CAD systems can be found in Zeid (1).

In this research, the ACIS solid modeler a Dessault Systemes product is used to model and manipulate geometry.

J. Comput. Inf. Sci. Eng 7(3), 192-202 (Jan 02, 2007) (11 pages) doi:10.1115/1.2752818 History: Received January 09, 2006; Revised January 02, 2007

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Mechanistic force model

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Figure 2

Uncut chip area decomposition

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Figure 3

Two-dimensional cross section of turning process

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Figure 4

Typical cutting tool inserts and generic cutting edge geometry

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Figure 5

Classifications of features generated from turning

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Figure 6

Classes of generic tool engagement features (teF)

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Figure 7

Material removal features (mrF) generated during turning

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Figure 8

Transient machining feature (trF)

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Figure 9

Hybrid TWE extraction methodology

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Figure 10

Solid modeler-based simulation methodology

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Figure 11

Tool construction geometry

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Figure 12

MRA decomposition

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Figure 13

Geometry invariant features

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Figure 14

teF extraction from giF

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Figure 15

Four types of form invariant feature fiF

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Figure 16

Area calculation of one example of teF

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Figure 17

Initial workpiece and final part solid models

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Figure 18

Simulation of the machining for various tool paths on example part

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Figure 19

Extracted mrFs for OP2

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Figure 20

teF extraction from fiF




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