A voxel-based kinematic simulation model for force analyses of complex milling operations such as wobble milling

Mechanical machining of fiber reinforced plastics poses special challenges due to the heterogeneous and anisotropic material composition. Process strategies for the generation of drill holes, which aim at directing the resultant process forces toward the center of the workpiece, have been shown to obtain good machining results with less process induced damage. However, these strategies (e.g. wobble milling) might involve complex multiaxial tool movements and are thus very difficult to analyze and optimize. A voxel-based kinematic simulation program has been set up, which allows analyses of process forces for arbitrary milling operations based on the time-resolved determination of the cutting thickness and multivariate process force regression models. A basic analysis of the process of wobble milling is presented as well. It confirms that the resultant process forces are directed toward the center of the workpiece when the outer material layers are machined. The resultant force is directed in a favorable direction throughout the complete cut during the actual process step of wobble milling.