DIGITAL GEOMETRY GENERATION OF HIGH PRECISION BROACHING TOOL CUTTING EDGES THROUGH IMAGE PROCESSING ALGORITHM

In this paper an efficient geometry description algorithm is proposed that reads the cutting-edge points of an arbitrary broaching tool from the provided model in a pixelated format which is surely available in any engineering environment. The created geometry can be scaled arbitrarily and used for simulations, ensuring adaptability due to its point cloud like format. High precision machining requires large resolution (microns) that often leads to unmanageable data storage needs with increased calculation time. To overcome these problems, the proposed algorithm is built around a pseudo arc-length-like continuation of the cutting-edge pixels, which works on broaching tools due to the cutting-edge geometry is free from any loops or isolas. This method provides all the important data including the high-resolution edge sections, related chip thicknesses and the normal directions for dynamic simulations and manufacturing.