A new geometric approach for real-time cutting force simulation in 3-axis ball-end milling compatible with graphical game engines

In this paper, a virtualized ball-end milling model is presented in Unity game engine environment, in which the machining process is simulated by proposing a new geometric approach. The model calculates and illustrates cutter-workpiece engagement area and cutting forces in a real-time manner. To calculate cutter-workpiece engagement, the workpiece surface is considered a set of nodes. Then, using a new geometric method, the engagement area is calculated at any node on the engaging surface. Utilizing the calculated engagement area and adopting mechanistic force model, the cutting forces applied from each node on the workpiece surface to the tool's cutting edge are calculated. Adopting the proposed new geometric method simplifies the mechanistic force model to such an extent that the cutting forces are calculated in a real-time manner. The extracted cutter-workpiece engagement areas have been compared with solid model results, and the cutting forces have been compared with the available experimental data. Good agreement between the results proved that the model can calculate the engagement area and cutting forces accurately. By changing the geometrical parameters of the model, it was shown that the speed of analyses can be increased to such an extent that the machining process can be simulated faster than 30 frames per second. The presented model is compatible with any game engine and can be used for augmented reality applications and machining process monitoring.