Prediction of Cutting Force in 3-Axis CNC Milling Machines Based on Voxelization Framework for Digital Manufacturing

A new digital-based model is presented for the prediction cutting forces in 3-axis CNC milling of surfaces. The model uses an algorithm to detect the work-piece/cutter intersection domain automatically for given cutter location (CL), cutter and work-piece geometries. The algorithm uses a voxelization framework to voxelize the cutter helix as well as the work-piece and based on voxel intersections between them can detect the tool engagement. Furthermore, an analytical approach is used to calculate the cutting forces based on the discretized model. The results of model validation experiments on machining PMMA and Aluminum 6061 are also reported. Comparisons of the predicted and measured forces show that this digital approach can be used to accurately predict forces during machining.