Virtual process systems for part machining operations

This paper presents an overview of recent developments in simulating machining and grinding processes along the NC tool path in virtual environments. The evaluations of cutter–part-geometry intersection algorithms are reviewed, and are used to predict cutting forces, torque, power, and the possibility of having chatter and other machining process states along the tool path. The trajectory generation of CNC systems is included in predicting the effective feeds. The NC program is automatically optimized by respecting the physical limits of the machine tool and cutting operation. Samples of industrial turning, milling and grinding applications are presented. The paper concludes with the present and future challenges to achieving a more accurate and efficient virtual machining process simulation and optimization system.