Fast Cutter Workpiece Engagement Estimation Method for Prediction of Instantaneous Cutting Force in Continuous Multi-Axis Controlled Machining

Abstract This study proposes a new efficient methodology to estimate an engagement between cutter of endmill and machined workpiece surface in continuous multi axis controlled machining process. In order to shorten calculation time for the engagement domain and realize real-time prediction of instantaneous cutting force, a new concept adapting ultra-parallel processing technology is proposed. In the proposed concept, the engagement domain is divided into a large number of estimation point. Then, inclusion estimation process between the estimation point and the machined workpiece volume is decomposed into simple estimation processes about tool swept volume. The developed prototype system shows good performance for complicate NC programs generated by commercial CAM system.