Hybrid cutting simulation via discrete vector model

Geometric cutting simulation and verification play an important role in detecting NC machining errors in mold and die manufacturing, thereby reducing the correcting time and cost on the shop floor. According to workpiece model, current researches may be categorized into view-based, solid-based, and discrete vector-based methods. Each methodology has its own strengths and weaknesses in terms of computing speed, representation accuracy, and its ability to perform numerical inspection. This paper proposes a cutting simulation methodology via a hybrid workpiece model which consists of the general discrete vector model and its simplified model. Workpiece modeling scheme, cutting simulation via tool swept surface modeling and vector intersection, and some case studies of mold and die machining are presented in this paper.