Coupled Dynamic Simulator with Tri-Dexel Milling Module for Robotic Machining Operations

In robotic machining, important tool-tip deviations occur resulting from lower stiffness as compared to CNC machines. Hence, this paper aims to present a coupled simulator developed in C++ for offline simulation of machine dynamics while operating, ultimately to estimate tool deviation and machined surface. The dynamic simulator of machine is coupled with a dexel-based machining module computing the forces as well as the updated workpiece geometry. The forces are computed by considering interference between dexel network and triangle-mesh sweep volume with relative closest triangle algorithm. Experimental milling tests are carried out for verification of forces, deviations and hence geometry.