A solid model-based milling process simulation and optimization system integrated with CAD/CAM

A solid model-based milling process simulation and optimization system integrated with CAD/CAM is developed for 3-axis end milling. In a commercial CAD/CAM environment, Unigraphics, solid models of part, blank and cutter are constructed and cutter location data (CLD) are generated. After CLD are interpreted, the swept volume of a cutter is intersected with the blank at every small segment along the tool path and the intersection is considered approximately as undeformed chip. Then chip parameters necessary for predicting milling force are extracted. Using an empirical model, milling force is predicted. While geometrically simulating material removing process, physical characteristics such as milling force are figured by curves. Then according to simulation results, feedrate can be optimized to satisfy productivity, quality and other requirements. The improvement can be seen from experiment results. Since the system is based on solid models and CLD, it can be applied to complex shape of parts and free cutting paths.