CNC simulation and machining of complex parts - Case study of a bullet profile

Virtual machining is an emerging technology for estimating the complex machining parameters of various parts before performing real-time machining in order to achieve dimensional accuracy, quality and reliability. This paper proposes an efficient methodology for visualizing the turning process of a complex bullet profile in the CAD/CAM system’s graphical interface. The 3D models of the bullet surface was created using CATIA Software. The CNC program was created from the CAD file in Siemens controller of the CNC Turning machine. The goal of this study was to compare simulation models of shape generation processes in turning operations of generated faces and real-world turning process experiments. Further virtual simulation of the bullet profile was conducted and compared with the experimental surface of the complex profile. The results confirmed that the simulation of virtual turning processes was nearly equivalent to the real-time turning experiments at the shop floor.