Prediction of time-varying instantaneous material removal volume with point cloud contour-filling model in milling process

IF 3.9 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Advances in Manufacturing Pub Date : 2025-06-13 DOI:10.1007/s40436-025-00563-y

Wen-Jun Lyu, Zhan-Qiang Liu, Bing Wang, Yu-Kui Cai, Ming Zhao, Hong-Xin Wang

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Abstract

Instantaneous material removal volume (IMRV) is a key parameter for predicting the cutting power, cutting force, and machining process. This paper presents a novel approach, known as the point cloud contour-filling method, for calculating the IMRV for each cutting tool edge at any instantaneous moment. Firstly, the kinematics during milling operations are analyzed to capture the exact motion trajectory envelope point cloud of the cutting tool edge. Secondly, the Z-map algorithm and Boolean operations are utilized to calculate the point cloud of the intersection between the workpiece and tool-edge trajectory envelope within unit time steps Δt (known as the IMRV point cloud). Finally, the 3D alpha method and Delaunay triangulation are employed to calculate the shape and volume of the IMRV. The proposed model considers the real tool-edge trajectory and tool installation errors, and introduces the variable of tool-workpiece engagement time t for the first time. The model is verified using milling tests. The proposed method provides a visualization of instantaneous complex engagement between the tool and workpiece during the milling process and can be further used for simulating milling forces and cutting power.

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用点云轮廓填充模型预测铣削过程中随时间变化的瞬时物料去除量

瞬时材料去除率（IMRV）是预测切削功率、切削力和加工过程的关键参数。本文提出了一种新的方法，称为点云轮廓填充法，用于计算任意时刻每个刀具边缘的IMRV。首先，对铣削过程中的运动学进行分析，获取刀具刃口的精确运动轨迹包络点云；其次，利用Z-map算法和布尔运算计算单位时间步长工件与刀具边缘轨迹包络相交的点云Δt（称为IMRV点云）。最后，采用三维alpha法和Delaunay三角剖分法计算了IMRV的形状和体积。该模型考虑了实际刀口轨迹和刀具安装误差，并首次引入了刀具与工件啮合时间t变量。通过铣削试验对模型进行了验证。该方法提供了铣削过程中刀具与工件之间瞬时复杂啮合的可视化，并可进一步用于模拟铣削力和切削功率。

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来源期刊

Advances in Manufacturing Materials Science-Polymers and Plastics

CiteScore

9.10

自引率

3.80%

发文量

274

期刊介绍： As an innovative, fundamental and scientific journal, Advances in Manufacturing aims to describe the latest regional and global research results and forefront developments in advanced manufacturing field. As such, it serves as an international platform for academic exchange between experts, scholars and researchers in this field. All articles in Advances in Manufacturing are peer reviewed. Respected scholars from the fields of advanced manufacturing fields will be invited to write some comments. We also encourage and give priority to research papers that have made major breakthroughs or innovations in the fundamental theory. The targeted fields include: manufacturing automation, mechatronics and robotics, precision manufacturing and control, micro-nano-manufacturing, green manufacturing, design in manufacturing, metallic and nonmetallic materials in manufacturing, metallurgical process, etc. The forms of articles include (but not limited to): academic articles, research reports, and general reviews.