Point-based tool representations for modeling complex tool shapes and runout for the simulation of process forces and chatter vibrations

Geometric physically-based simulation systems can be used for analyzing and optimizing complex milling processes, for example in the automotive or aerospace industry, where the surface quality and process efficiency are limited due to chatter vibrations. Process simulations using tool models based on the constructive solid geometry (CSG) technique allow the analysis of process forces, tool deflections, and surface location errors resulting from five-axis machining operations. However, modeling complex tool shapes and effects like runout is difficult using CSG models due to the increasing complexity of the shape descriptions. Therefore, a point-based method for modeling the rotating tool considering its deflections is presented in this paper. With this method, tools with complex shapes and runout can be simulated in an efficient and flexible way. The new modeling approach is applied to exemplary milling processes and the simulation results are validated based on machining experiments.