Computation of Instantaneous Cutter Engagement in 2.5D Pocket Machining

Cutting force and cutter-workpiece engagement (CWE) evolve similarly during 2.5D milling operations. Therefore, CWE is related with the efficiency of a pocket machining. We propose an algorithm to approximate CWE by means of the engagement arc length. This arc is determined by the intersection between a disk (the end mill), and the machined area obtained by Boolean operations. Our procedure is easy to implement, and the computed CWE behaves as the cutting force measured in real tests.