A solid-analytical-based model for extracting cutter-workpiece engagement in 5-axis flank machining

5-axis flank milling is applied extensively in aerospace, die-molds, and automotive industries because of high efficient material removal rate. Commercial CAM software can only simulate the tool path and collision at present, but cannot handle with cutting force during cutting process due to the variable geometrical cutter workpiece engagement (CWE) region of 5-axis milling. This paper presents a novel solid analytical model for extracting the CWE maps. The CWE is obtained analytically by performing Boolean operations between the cutter and inprocess-workpiece (IPW) at any given cutter location (CL) point, instead of using the cutter and the removal volume. The proposed process simulation method could identify the CWE efficiently and precisely for general cutting tools. Finally, the CWE boundaries are mapped from a 3D space into a 2D plane defined by the immersion angle and the axial depth of a given cutter. The proposed solution can be easily integrated into the CAM software for predicting milling force and optimizing parameters in 5-axis milling.