Identification of rake and flank face engagement parameters using a dexel-based material removal simulation with an oriented sweep volume

This paper presents an approach for the simulation of cutting processes with a dexel based-simulation considering process damping. The approach allows an independent modeling of engagement parameters for both rake and flank faces of arbitrary tool and workpiece geometries including dynamic behavior for the first time. A method is introduced for calculating the indentation volume of the flank face independently of the rake face. Therefore, the oriented sweep volume is introduced. The indentation volume of the flank face is used to model process damping for improving stability and dimensional form error prediction. For verification, experimental milling tests are carried out to create stability charts and surfaces. Both, the stability and surface prediction of the approach are analyzed for a chamfered tool, where a flank face - workpiece contact occurs, and an unchamfered tool, where no flank face - workpiece contact occurs. Even though the prediction accuracy of the stability limit can be improved compared to different approaches, there are significant differences between simulation and experiment. Thus, there is still a high need for a more accurate modelling of the process damping effect.