Five-axis Milling Simulation And Research On Material Remove Rate Optimization Based On ACIS

This thesis researches on tool swept volume generation, cutter-workpiece engagementand material remove rate optimization in five-axis milling simulation. And a five-axis millingsimulation software based on tool swept volume is developed. The main achievements are asfollowings:1. Having researched tool swept volume generation in five-axis milling. Using envelopetheory and moving frame of axes, the swept outline on tool surface is solved by analyticmethod. And tool swept volume is formulated by using skin method of geometric modelingfor the solved swept outline.2. Having researched self-intersection in swept volume generation. Self-intersection ofenvelope surface will lead to the non-manifold of swept volume boundary. This thesisemploys geometric method to determine self-intersection of swept outline, and uses discretemodeling to solve self-intersection.3. Having researched material remove rate optimization. Material remove rate betweentwo adjacent tool positions in cutting process is solved. And the optimization target ofmaterial remove rate is achieved by planing cutting feed and decreasing cutting row spacing.4. Having researched cutter-workpiece engagement. Feasible contact surfaces are solvedby empolying tool swept volume generation method. And cutter-workpiece is obtained byusing geometric method and boolean operation between feasible contact surfaces andin-process workpiece.On the basis of theoretical achievements of this thesis, a five-axis milling simulationsoftware based on tool swept volume is developed by Visual Studio2005, ACIS/HOOPS andC++programming. And the software function is verified by simulation example.