Modeling of Surface Location Errors in a Multi-scale Milling Simulation System Using a Tool Model Based on Triangle Meshes

Simulation systems are used to optimize milling processes by analyzing surface location errors, which can be predicted by combining various modeling techniques in a multi-scale way. In order to visualize surface location errors, a multi-dexel representation of the workpiece can be used. The application of a triangle mesh representation of the tools to cut the workpiece model is presented, which results in a higher accuracy of the predicted surface location errors in comparison to a Constructive-Solid-Geometry-(CSG)-based approach. Both models are evaluated by simulating a milling process and the simulation results are validated by comparing them to experimental results.