Abstract

This paper presents a real time simulation for virtual end milling process. A virtual end milling process was simulated and the flank wear graphs of the cutting tools can be visualized during the machining process. The prototype of the 3D virtual environment which is based on the standalone concept has been developed using AutoCAD 2002, VRML Out, VRML Pad, JavaScript and Java. AutoCAD 2002 was used to model the 3D objects and then the models were transformed into VRML format using VRML Out. Java, JavaScript and VRML were used to develop the animation of end milling process simulation and machining parameters simulation such as the flank wear on cutting tools. The simulation for the geometrical modeling of end milling process and analytical modeling of machining parameters was developed based on real data from some experiments using Computer Numerical Control (CNC) milling machine. The experiment for this study is divided into two categories, 100% full engagement milling and 15% engagement down milling with two different types of feed rate, 0.02 mm/rev and 0.04 mm/rev. This application can simulate the virtual end milling process and real time graph of flank wear (mm) against cutting time (min) on tool cutter simultaneously. The user can also analyze parameters that influenced the machining process such as cutting speed, feed rate of worktable or types of engagement against the flank wear on cutting tools and the tool life of cutting tools used.

Original languageEnglish
Pages (from-to)148-156
Number of pages9
JournalEuropean Journal of Scientific Research
Volume24
Issue number1
Publication statusPublished - 2008

Fingerprint

Cutting tools
Machining
Wear of materials
Milling (machining)
simulation
Simulation
JavaScript
Milling machines
Animation
Virtual reality
Java
Experiments
Real-time Simulation
Numerical Control
Analytical Modeling
cutters
Computer Experiments
Process Simulation
Process Modeling
Graph in graph theory

Keywords

  • End milling process
  • Flank wear
  • Simulation
  • Virtual reality

ASJC Scopus subject areas

  • General

Cite this

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title = "Flank wear simulation of a virtual end milling process",
abstract = "This paper presents a real time simulation for virtual end milling process. A virtual end milling process was simulated and the flank wear graphs of the cutting tools can be visualized during the machining process. The prototype of the 3D virtual environment which is based on the standalone concept has been developed using AutoCAD 2002, VRML Out, VRML Pad, JavaScript and Java. AutoCAD 2002 was used to model the 3D objects and then the models were transformed into VRML format using VRML Out. Java, JavaScript and VRML were used to develop the animation of end milling process simulation and machining parameters simulation such as the flank wear on cutting tools. The simulation for the geometrical modeling of end milling process and analytical modeling of machining parameters was developed based on real data from some experiments using Computer Numerical Control (CNC) milling machine. The experiment for this study is divided into two categories, 100{\%} full engagement milling and 15{\%} engagement down milling with two different types of feed rate, 0.02 mm/rev and 0.04 mm/rev. This application can simulate the virtual end milling process and real time graph of flank wear (mm) against cutting time (min) on tool cutter simultaneously. The user can also analyze parameters that influenced the machining process such as cutting speed, feed rate of worktable or types of engagement against the flank wear on cutting tools and the tool life of cutting tools used.",
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