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UBC Theses and Dissertations

Virtual turning system Zhou, Jing

Abstract

The goal of machining industry is to produce the first part correctly and most optimally without resorting costly trials on the shop floor. This thesis presents a Virtual Turning system which predicts the physics of machining rotational parts before actual production on the shop floor. As opposed to measurement of physical dimensions, cutting forces, torque, and power, they are predicted in virtual environment by integrating the laws of metal cutting process and the geometric and solid modeling of the tool-workpiece engagements along the tool path. The proposed Virtual Turning has two fundamental modules. The first module identifies the tool-workpiece engagement geometry along the path, which is used by the second, cutting process simulation engine. The initial workpiece geometry and tool path (Cutter Location) are imported from commercial CAD/CAM systems using industry standard IGES or STEP NC graphics formats. The tool-workpiece intersections along the tool path are identified by applying Boolean intersections of the two parts represented by their Boundaries. In order to expedite the time consuming computations, the in-process machining features along the path are classified, engagement conditions are parametrically modeled, and recalled instead of using Boolean operations recurrently along the tool path. The proposed hybrid model which consist of tool-workpiece engagements modeled by features or solid to solid intersections, can handle turning of a verity of two dimensional, symmetric rotational parts.

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