Five-axis milling simulation based on B-rep model

Abstract

Formulating the swept volume by a cutter along its path plays an important role in volumetric simulation of five-axis machining. In some cases, the swept volume may experience self-intersection, which is a crucial issue and difficult to be solved. Based on B-rep model, this paper proposes an algorithm for formulating the swept volume for five-axis ball-end milling, including a method for solving the self-intersection. Simulation shows the proposed method can be robustly used for five-axis material remove simulation with large tool orientation changes, and calculating the material remove rate as well as evaluating machining precision. © 2011 Springer-Verlag.