Complex Surface Representation and Machining Time Estimation Upon Three Types of End Mill Cutter


The accuracy of data transition between CAD and CAM has been playing a great role in the product life cycle, and eventually, the product quality. As products complexity increased, the need to robust technique to data transition increased. On the other hand, Machining simulation facilitates deciding the process parameters. The aim of the present research is divided into two aims: first: building a free form surface and transforming its data accurately from CAD to CAM without any distortion. Second: study the milling process using different end cutters geometry and make a comparison between those in terms of machining time at a constant scallop height (s.h.). The study passed through three steps, first: A mathematical model and computer program had been built for non-uniform B-spline surface creation. The output points are stored in a format to be easily imported. Second: importing the data into manufacturing simulation program to emulate the milling process. Three types of milling tools with different end cutter had been used (flat, ball, and toroidal). Third, use a CIMCO edit package to estimate machining time for the three tools. A conclusion had been made that the surface data had been transformed accurately into the simulation process. Another conclusion was, with fixed (s.h.) the ball end mill takes more time than toroidal, which in turn takes more time than flat