Study on Calculation Error of the Material Removal Volume in Z-map Based Machining Simulation

This paper deals with the discrete error analysis of material error calculation in Dynamic Machining Simulator (DMS). DMS can simulate the material removal per tool revolution in a real-time fashion when the tool moves along the path defined by a CNC program. Based on calculated removal rate, the feed rate is optimized so that the loading to the tool can be maintained at the permissive maximum value. In this simulation technique, the accuracy of the material removal calculation which is to be performed in a discrete manner, is very important to achieve the reliable control. In this study, the algorithm for error analysis is developed and optimum values of simulation parameters are determined for three typical end mill operation.