Efficient topography simulation for freeform surfaces in 5-axis CNC milling

Zekalmi, Yasser (Universidad de Zaragoza) ; Albajez, José Antonio (Universidad de Zaragoza) ; Oliveros, María José (Universidad de Zaragoza) ; Aguado, Sergio (Universidad de Zaragoza)

Resumen: Accurate prediction of surface micro-topography in 5-axis CNC milling is essential for achieving high-quality finishes in aerospace, biomedical, and precision engineering components. Traditional simulation methods like the Classical Z-Map often suffer from high computational cost and limited applicability to freeform surfaces. This paper presents RMAP, a fast and vectorized algorithm that enhances the Classical Z-Map by projecting cutter edge points in a locally transformed coordinate system aligned with the surface normal. The method supports arbitrary machining strategies exported from CAM software and is compatible with both ideal and realistic cutter edge geometries. Simulations were performed on a hyperbolic paraboloid surface using tool paths generated in NX CAM and validated experimentally on aluminum. RMAP achieved speedups up to 100x compared to Classical Z-Map, with relative errors below 6\% for key areal experimental parameters Sa and Sq. Notably, simulations incorporating realistic cutter edge imperfections, modeled with a stochastic distribution, accurately reproduced short-wavelength directional features observed in experimental measurements. The algorithm proved robust across multiple strategies, including 3-axis and 5-axis configurations with variable feed rates. By maintaining accuracy on complex freeform geometries and significantly reducing computation times, RMAP enables reliable and scalable topography simulation.

Idioma: Inglés

DOI: 10.1007/s00170-025-16013-9

Año: 2025

Publicado en: INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY (2025), [18 pp.]
ISSN: 0268-3768

Financiación: info:eu-repo/grantAgreement/ES/DGA/T56-23R
Financiación: info:eu-repo/grantAgreement/ES/NextGenerationEU/INVESTIGO-094-77
Financiación: info:eu-repo/grantAgreement/ES/UZ/JIUZ2023-IA-01

Tipo y forma: Article (PostPrint)

Área (Departamento): Área Ing. Procesos Fabricación (Dpto. Ingeniería Diseño Fabri.)