Abstract

Modelling the volume swept by a tool as it moves from one programmed position to another in three, four and five-axis milling is a challenging task. In this paper, a technique for generating the volume swept by a toroidal cutter in its motion along a given tool path, is presented. This technique is based on identifying “generating curves” along the path and connecting them into a solid model of the swept volume. The swept volume simulations are verified experimentally for three test pieces. These are also compared with the simulation results from the Z-map technique. The results of the experimental verification show the method to be accurate to within 10 μm for the three test pieces. Furthermore, the computation time for the new technique is significantly less than the Z-map method. It is concluded that the proposed method has the potential of allowing fast simulation and verification of multi-axis tool paths.

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