Combining Different Modeling Techniques to Optimize the Simulation of the Five-Axis Milling Process

Zabel, A.1, a; Odendahl, S.1, b; Peuker, A.1, c

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund

a); b); c)


The need for efficiency and process stability in the small-batch manufacturing of dies and molds leads to increasing demands on the process planning. For this purpose, a multi-scale milling simulation has been developed, which combines the advantages of different approaches to the modeling of the simultaneous five-axis milling process. With this simulation system, it is possible to efficiently analyze entire machining steps using a multi-dexel-board approach for the workpiece and switch to a more detailed simulation method whenever it is expedient to get more precise information about the cutting forces and the dynamic behavior of the machine. This detailed examination is performed using the Constructive Solid Geometry modeling technique, which also provides the possibility to predict the generated surface structure.


Simulation, Milling, Geometric Modeling


In: Proceedings of the 5th International Conference and Exhibition on Design and Production of Machines and Dies/Molds, 18.6.-21.6. 2009, Kusadasi, Turkey, Kaftanoglu, B. (Hrsg.), ISBN 978-605-60732-0-5, S. 155-160