document: Generic simulation approach for multi-axis machining . Part 1 : modeling methodology This paper presents a new methodology for analytically simulating multi-axis machining of complex sculptured surfaces . A generalized approach is developed for representing an arbitrary cutting edge design , and the local surface topology of a complex sculptured surface . A NURBS curve is used to represent the cutting edge profile . This approach offers the advantages of representing any arbitrary cutting edge design in a generic way , as well as providing standardized techniques for manipulating the location and orientation of the cutting edge . The local surface topology of the part is defined as those surfaces generated by previous tool paths in the vicinity of the current tool position . The local surface topology of the part is represented without using a computationally expensive CAD system . A systematic prediction technique is then developed to determine the instantaneous tool/part interaction during machining . The methodology employed here determines the cutting edge in-cut segments by determining the intersection between the NURBS curve representation of the cutting edge and the defined local surface topology . These in-cut segments are then utilized for predicting instantaneous chip load , static and dynamic cutting forces , and tool deflection . Part 1 of this paper details the modeling methodology and demonstrates the capabilities of the simulation for machining a complex surface
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