Abstract
Today, complex freeform surfaces are widely used on parts in automobile, aerospace, and die– mold industries. Multi-axis computer numerical control (CNC) machines are used to manufacture such parts as they need tighter tolerances and high surface finish to meet functional and aesthetic requirements. Scallop height is primarily used to measure and assess the surface quality of such products. The inspection methods used in practice are expensive and need experienced personnel. No simulation techniques exist, as of now, to estimate the part quality apriori. This paper reports the development of an algorithm to estimate the scallop heights for freeform surface machining from the CNC part programs. The developed system takes STL file of the simulated machined component from the VERICUT and slices it along the specified planes. Points so generated are analyzed to estimate scallop heights at various regions on the surface using numerical curve-fitting techniques. The developed system has been validated with the case studies. The system provides a robust and accurate estimation of the part quality.
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