Analytical cut geometry prediction for free form surface during semi-finish milling

In five-axis milling, determination of continuously changing Cutter Workpiece Engagement (CWE) is still a challenge. Solid model and discrete model are the most common method used to predict the engagement region. However, both methods are suffering with the long computational time. This paper presents an analytical method to define CWE of toroidal cutter during semi-finishing of sculpture part. The workpiece from 2.5D rough milling is represented by a number of blocks. The length of cut at every engagement angle can be determined by calculating the outermost engagement point called upper CWE point. This point was determined by first assumed that the workpiece surface is flat. A recalculation for CWE correction is then performed for the engagement occurred in two workpiece blocks. The method called Z-boundary and X-boundary are employed to obtain the upper CWE point when the engagement occurred on toroidal side. Meanwhile Cylinder-boundary method was used when the engagement occurred on the cylinder side. The developed model was examined to ensure its accuracy. A sculptured surface part was tested by comparing the depth of cut generated by the simulation developed and the depth of cut measured by Unigraphic. The result indicates that the proposed method is very accurate. Moreover, due to the method is analytically, and hence it is efficient in term of calculation time.