Virtual machining

Abstract

Virtual machining simulates NC code to discover errors, without a time consuming trial run or online debugging on real machine tool. Since machining is a material removal process that will deform the workpiece geometry with cutting, the traditional rigid geometrical model could not be used to describe the in-process status of workpiece, which changes shape continually. The evolution of deformable workpiece model from the 2D sections to 3D representations revolutionized not only the machining industry, but also pioneered the digital manufacturing age with virtual manufacturing. This chapter traces back the history of CNC simulation, analysis of the different CNC machining models, tested with application examples, and lists different CNC verification industry applications for the last 30 years. Working towards a vision of pervasive modelling and simulation, a unified voxel-based in-process geometry model for multiple-machining and 3D printing simulations is discussed with industrial applications of composite material plating simulation. The virtual machine tool, which includes material removal animation and machine kinetic movement, can be controlled with a virtual CNC control panel and equipped with virtual jigs and inspection tools, such as dial indicator and wiggler, for immersive training of a young machinist. Towards a competitive sustainable manufacturing future, pervasive applications of virtual machining are not only technologically possible, but also make business sense, in this high material and energy cost world.