Abstract
This paper presents an efficient method of computing machined part geometry in general multi-axis milling. The method is based on the frame-sliced voxel representation of the workpiece geometry and involves a three-step update process. Virtual prototyping of the machined part geometry is useful for tool path verification and demands fast computations for quick feedback. The frame-sliced voxel representation (FSV-rep) model retains the advantages of efficiency and robustness of voxel modeling in model update along with the accuracy and boundary representation quality comparable to that of triangle meshing. The multi-level FSV-rep model allows a three-step update process of the model, which enables batch processing of the voxels and minimal intersection calculations to achieve fast and accurate modeling results. In a series of test cases, the FSV-rep-based computation has shown up to 3.3 times faster performance compared to that of the existing tri-dexel-based method with similar modeling accuracy. The better performance of the present method is attributed to the bulk workpiece volume to be removed and the complex multi-axis motions of the cutting tool with tilted orientations.
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