Machine models and tool motions for simulating five-axis machining
Mechanistic modelling of surface machining with a toroidal end mill is presented in this work for 5-axis machining. A graphical representation of tool movements (using tooth swept sectors or the swept surface of the tool) is rendered using a widely available rendering engine, whereby the in-process chip geometry and tool edge contact length are determined by an adaptive and local depth buffer. Owing to the chip geometry being highly dependent on the feedrate, a detailed derivation of the relative tool-workpiece velocity is presented based on the kinematics of a tilt-rotary table configuration. The mechanistic modelling is verified with experimental results and found to agree to within 7% of the peak-to-peak forces.