Details
| Original language | English |
|---|---|
| Pages (from-to) | 41-45 |
| Number of pages | 5 |
| Journal | Procedia CIRP |
| Volume | 4 |
| Publication status | Published - 20 Nov 2012 |
| Event | 3rd CIRP Conference on Process Machine Interactions, PMI 2012 - Nagoya, Japan Duration: 29 Oct 2012 → 30 Oct 2012 |
Abstract
A new method for analyzing the tool-workpiece-contact area in cutting processes is presented. To gain enhanced knowledge about tool-workpiece interaction, determination of chip thickness, contact length and resulting cross-section area of the undeformed chip is of major interest. Compared to common simulation approaches, where rotation-symmetrically constructed tool geometry is used, the new method uses a detailed three dimensional tool shape model for an extended and more accurate contact zone analysis. As a corresponding representation of the workpiece and its time dependent shape-changes a multidexel model is used. To prepare the geometric tool model, the contained BREP topology is built up within the simulation system using data from a STEP-file. First of all functional parts of the tool like rake and flank faces and cutting edges are labeled for further processing. In a second step the identified NURBS-faces are discretized for the application in material-removal calculation. This way a mesh is built-up based on triangle elements which maps the geometry of each cutting edge into a 2D parametric representation. In relation to rake face, each node is described by its position on the cutting edge and its perpendicular distance to this edge. To perform contact zone analysis each cutting geometry and a multidexel model are intersected in discrete time steps corresponding to a tool rotation of about three degrees. The intersection point of each dexel and the cutting geometry is calculated. Parametric cutting geometry allows for a direct computation of local cutting depth and contact length for each involved point. Based on the local values of contact length and cross section area of the undeformed chip the characteristic values for the entire contact zone are calculated and used to predict mechanical as well as thermal loads caused by the cutting process. To demonstrate the application of the novel approach, prediction of forces in slot milling of 1.1191 steel is presented.
Keywords
- BREP model, Force calculation, Graphics hardware (GPU), Multidexel model, NC-simulation, Tool stress
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Procedia CIRP, Vol. 4, 20.11.2012, p. 41-45.
Research output: Contribution to journal › Conference article › Research › peer review
}
TY - JOUR
T1 - Contact Zone Analysis Based on Multidexel Workpiece Model and Detailed Tool Geometry Representation
AU - Boess, V.
AU - Ammermann, Chr
AU - Niederwestberg, D.
AU - Denkena, B.
PY - 2012/11/20
Y1 - 2012/11/20
N2 - A new method for analyzing the tool-workpiece-contact area in cutting processes is presented. To gain enhanced knowledge about tool-workpiece interaction, determination of chip thickness, contact length and resulting cross-section area of the undeformed chip is of major interest. Compared to common simulation approaches, where rotation-symmetrically constructed tool geometry is used, the new method uses a detailed three dimensional tool shape model for an extended and more accurate contact zone analysis. As a corresponding representation of the workpiece and its time dependent shape-changes a multidexel model is used. To prepare the geometric tool model, the contained BREP topology is built up within the simulation system using data from a STEP-file. First of all functional parts of the tool like rake and flank faces and cutting edges are labeled for further processing. In a second step the identified NURBS-faces are discretized for the application in material-removal calculation. This way a mesh is built-up based on triangle elements which maps the geometry of each cutting edge into a 2D parametric representation. In relation to rake face, each node is described by its position on the cutting edge and its perpendicular distance to this edge. To perform contact zone analysis each cutting geometry and a multidexel model are intersected in discrete time steps corresponding to a tool rotation of about three degrees. The intersection point of each dexel and the cutting geometry is calculated. Parametric cutting geometry allows for a direct computation of local cutting depth and contact length for each involved point. Based on the local values of contact length and cross section area of the undeformed chip the characteristic values for the entire contact zone are calculated and used to predict mechanical as well as thermal loads caused by the cutting process. To demonstrate the application of the novel approach, prediction of forces in slot milling of 1.1191 steel is presented.
AB - A new method for analyzing the tool-workpiece-contact area in cutting processes is presented. To gain enhanced knowledge about tool-workpiece interaction, determination of chip thickness, contact length and resulting cross-section area of the undeformed chip is of major interest. Compared to common simulation approaches, where rotation-symmetrically constructed tool geometry is used, the new method uses a detailed three dimensional tool shape model for an extended and more accurate contact zone analysis. As a corresponding representation of the workpiece and its time dependent shape-changes a multidexel model is used. To prepare the geometric tool model, the contained BREP topology is built up within the simulation system using data from a STEP-file. First of all functional parts of the tool like rake and flank faces and cutting edges are labeled for further processing. In a second step the identified NURBS-faces are discretized for the application in material-removal calculation. This way a mesh is built-up based on triangle elements which maps the geometry of each cutting edge into a 2D parametric representation. In relation to rake face, each node is described by its position on the cutting edge and its perpendicular distance to this edge. To perform contact zone analysis each cutting geometry and a multidexel model are intersected in discrete time steps corresponding to a tool rotation of about three degrees. The intersection point of each dexel and the cutting geometry is calculated. Parametric cutting geometry allows for a direct computation of local cutting depth and contact length for each involved point. Based on the local values of contact length and cross section area of the undeformed chip the characteristic values for the entire contact zone are calculated and used to predict mechanical as well as thermal loads caused by the cutting process. To demonstrate the application of the novel approach, prediction of forces in slot milling of 1.1191 steel is presented.
KW - BREP model
KW - Force calculation
KW - Graphics hardware (GPU)
KW - Multidexel model
KW - NC-simulation
KW - Tool stress
UR - http://www.scopus.com/inward/record.url?scp=84883896183&partnerID=8YFLogxK
U2 - 10.1016/j.procir.2012.10.008
DO - 10.1016/j.procir.2012.10.008
M3 - Conference article
AN - SCOPUS:84883896183
VL - 4
SP - 41
EP - 45
JO - Procedia CIRP
JF - Procedia CIRP
SN - 2212-8271
T2 - 3rd CIRP Conference on Process Machine Interactions, PMI 2012
Y2 - 29 October 2012 through 30 October 2012
ER -