Voxel-based modeling of transient material removal in machining

In the present study, a novel framework is presented that models the transient interaction between cutting teeth of an arbitrary end mill geometry and a workpiece. In this framework, the workpiece geometry is modeled using a voxelized representation that is dynamically updated as material is locally removed by each tooth of the cutting tool. A ray casting approach was used to mimic the process of the cutting faces of the tool intersecting the workpiece material. This ray casting approach was used to calculate the instantaneous undeformed chip thickness. The resulting voxel-based model framework was validated by comparison of predictions with experimentally measured milling forces. The effect of voxel size on model predictions was evaluated, and the ability of the model to describe the interactive effects of sequential machining passes was also investigated. Implications of this voxel-based model framework in terms of utility for predicting local surface finish and computational scalability of complex cutting configurations are briefly discussed.