Distortions prediction during multi-pass machining simulations by using the level-set method

In this presentation, an innovative approach for the representation of machining cutting paths based on the level-set method is proposed. During most machining processes, the highest level of distortions usually comes from relaxation of residual stresses so that a simulation at the global scale (i.e.: without taking into account chip forming and tool/workpiece interactions) is sufficient for the prediction of shape error. A classical finite elements approach requires that the workpiece mesh matches the different cutting paths. Furthermore, given the fact that cutting paths are given in the initial configuration while the workpiece deforms during the process, numerous remeshing steps are needed. On the contrary, making use of the level-set (signed distance map) enables to define independently cutting paths and workpiece mesh; only the level-sets need to be recomputed between two operations.