Model-based cutting simulation system for prediction of cutting states

This paper describes a cutting simulation system which has the function of physical simulations as well as geometrical simulations. In the geometrical simulation, changes in workpiece geometry in the course of cutting processes are evaluated based on a solid modeling system. In the physical simulation, physical parameters of cutting processes are evaluated based on physical models. Instantaneous cutting force can be estimated by composing cutting force vectors acting on infinitesimal parts of flutes. Cutting error is then estimated based on tool deflections induced by the cutting force. A system for simulating the cutting process using a square end mill cutter has been developed based on a geometric modeler with boundary representations. A number of cutting experiments were conducted for various tools and cutting conditions. The results of experiments proved the accuracy of estimations by the simulation system.