Direct computation of instantaneous cutting force in real-time multi-axis NC simulation

Cyber physical system (CPS) requires modeling and virtual simulation of machining processes. Among the many physical quantities simulated by CPS, the cutting force is one of the most important quantities to be simulated. Until now, two fundamental challenges in achieving a functional and virtual machining process simulation system remain—the identification of cutter workpiece engagement (CWE) along a tool path and the development of computationally efficient simulation algorithms. The major bottleneck is the prerequisite requirement to calculate the complex CWE area before calculating the instantaneous cutting force. In this research, we propose an innovative solution to this problem. Using graphics processing unit’s (GPU) parallel computing on the direct computation of the instantaneous cutting force (without calculating CWE), the cutting force computation, together with NC simulation, can reach up to 48 fps on a local PC, reaching the goal of CPS and digital twin simulation requirements in real time.