Extraction of Cutter-Workpiece Engagement for Multi-Axis Milling

Cutter-workpiece engagement (CWE) is the contact zone where the cutting flutes enter and exit the workpiece as a function of axial depth of cut. Determination of CWE is the basis for predictions of cutting forces, machining error and chatter stability in multi-axis milling. In this paper, a solid modeling approach is developed to extract CWE for multi-axis milling by means of removal volume, which is obtained by subtracting analytic tool swept volume from in-process workpiece. Meanwhile, the feasible contact surfaces are used to trim the removal volume in order to determine CWE surfaces. Simulations are also performed to confirm the validity of the proposed method.