Three-axis NC milling simulation based on adaptive triangular mesh

NC milling simulation has become an important step in computer aided manufacturing (CAM). To achieve real-time simulation, the total number of polygons has to be reduced, which results in poor image quality. This paper presents an adaptive triangular mesh algorithm to reduce the number of polygons while image quality remains high. Binary tree is used to represent the milling surface, and the optimization of the mesh is performed dynamically in the process of simulation. In this algorithm, the resolution of triangles is automatically updated according to local surface flatness, thus greatly reducing the number of triangles at planar regions. By doing this, real-time and high quality of visual presentation is insured and the translation, rotation and zooming operations are still applicable. When machining precision is evaluated, or overcut, undercut and interference are inspected, full resolution model stored in memory is automatically loaded to ensure the accuracy and correctness of these inspections. Finally, an example is presented to illustrate the validity of proposed algorithm.