Complete swept volume generation - Part II: NC simulation of self-penetration via comprehensive analysis of envelope profiles
In this paper the swept volume with self-penetration (or self-intersection) of the cutter is presented. The complete swept volume (SV), which describes the side and bottom shape of a milling cutter undergoing self-penetration, is generated by using the Gauss map method proposed in the authors previous paper [Lee SW. Nestler A. Complete swept volume generation part I: swept volume of a piecewise C(1)-continuous cutter at five-axis milling via Gauss map. Computer-Aided Design 2011:43(4): 427-41]. Based on the Gauss map method, the comprehensive analysis of envelope profiles of the tool is accomplished. Through the analysis the necessary condition of the self-penetration of the cutter at five-axis movement is identified. After having classified movement types of the milling cutter in an in-depth manner, the topologically consistent boundary of SV is generated by trimming the invalid facets interior to the SV. To demonstrate the validity of the proposed method, a cutting simulation kernel for five-axis machining has been implemented and applied to cavity machining examples such as intake ports of automobile engines and so forth where the self-penetration occurs. The proposed method is proved to be robust and amenable for the practical purpose of the NC simulation. (C) 2011 Elsevier Ltd. All rights reserved.
swept volume nc simulation self-penetration envelope profile self-intersection solid modeling