SUMMARY

In this manuscript, a voxel based model for the interaction between cutting teeth of an arbitrary end mill geometry and a workpiece is developed that allows for the virtual machining of workpiece volumes with generated tool geometry. In this framework, the workpiece geometry is modeled using a voxelized representation that is dynamically updated as material is locally removed by each tooth of the cutting tool. A ray casting approach is then used to mimic the process of the cutting faces of the tool raking out workpiece material. This ray casting regime is also used to calculate the instantaneous undeformed chip thickness. The resulting voxel based model framework was validated by comparison of predictions with experimentally measured milling forces. The results demonstrate the model’s ability to accurately simulate the interaction of cutting teeth with the bulk material of the workpiece. The model is further expanded to simulate the impact of previous tool passes on subsequent one. Implications of this new voxel based model framework are briefly discussed in terms of utility for predicting local surface finish and computational scalability of complex cutting configurations.