A novel cutting simulation method based on Dexel model integrating oct-tree acceleration and enhanced prism meshing

Real-time cutting simulation in CNC(Computerized Numerical Control) machining has become indispensable for guaranteeing machining accuracy and collision avoidance. However, real-time cutting simulation faces critical computational bottlenecks in discrete geometric modeling, particularly in Dexel model generation where ray-triangle intersection calculations show poor efficiency with complex models, and in mesh reconstruction where traditional sorting-based algorithms exhibit O(n²) efficiency degradation at high resolutions. To address these challenges, this paper proposes a novel cutting simulation method based on Dexel model integrating oct-tree acceleration and enhanced prism meshing. Firstly, an oct-tree spatial indexing strategy is put forward, which optimizes ray-object intersection calculations through ray grouping and face-area sorting, aiming to reduce Dexel generation time. Secondly, the tetrahedral prism meshing algorithm is enhanced by introducing an event-driven region partitioning method and corresponding endpoints connection rules, eliminating sorting efficiency bottleneck in meshing. Rigorous case studies demonstrate approximately 90% reduction in Dexel generation time and 75% reduction in mesh generation time compared to traditional methods, enabling real-time high-resolution cutting simulation.