Scanning and modeling for non-standard edge geometry endmills

This paper describes a reverse engineering solution for modeling the behavior of non-standard edge geometry endmills. Structured light scanning is used to produce a solid model of the endmill and spatial coordinates for the points that define the cutting edges are extracted. These points are used to determine the cutting edge radius and angle at equally spaced points along the tool’s axis. This cutting edge geometry is then incorporated in a time domain simulation that predicts cutting force and tool/workpiece deflection for user-selected operating parameters. Good agreement between predicted and measured cutting forces is first demonstrated. Second, the results of stability tests are compared to simulation predictions for multiple spindle speed-axial depth of cut combinations. The time records are analyzed by periodically sampling the measured and predicted displacement and velocity.