Geometric Simulation of 5-Axis Machining With Descrete Placement of Tool Models

This study reports on the development of a geometric simulation method for 5-axis machining that eliminates the need for tool swept volume in the calculation. This method repeatedly subtracts the tool shape model, which gradually changes its position and posture along the cutter path, from the workpiece model to obtain the workpiece shape after machining. This method was commonly used in early machining simulation software, but had a disadvantage that the tool spacing had to be sufficiently small to obtain accurate results, leading to high computational costs. The current research differs from previous studies in three key aspects: (1) it leverages the parallel processing function of the graphics processing unit to achieve high processing speeds, (2) it clarifies the relationship between tool spacing and calculation accuracy to achieve optimal tool placement, and (3) it employs a highly accurate polyhedral representation of the tool shape to realize a general-purpose method that can be applied to any cutting tools.