Article: High-precision CAD-based simulation for turning considering tool microgeometry Journal: International Journal of Mechatronics and Manufacturing Systems (IJMMS) 2023 Vol.16 No.1 pp.83 - 95 Abstract: Surface roughness is considered to be a critical parameter when evaluating the machinability of a material, as well as the surface quality of a machined part. Thus, a number of studies exist in the literature, that deal with the simulation and prediction of the surface roughness generation during machining. This paper presents a 3D simulation method for turning, considering the full geometrical aspects of a cutting-tool, leading to highprecision simulation of the process. For the purposes of the study, a commercially available, generic CAD system was utilised, namely SolidWorks™. Specifically, the application programming interface (API) of the software was used, to write code that is capable of simulating the kinematics of the turning process. In addition, the surface roughness profile, topography, as well as typical measurements were generated, with respect to machining conditions such as, depth of cut, feed and cutting speed. For the verification of the accuracy of the code, a set of nine turning experiments were carried out, for a specified range of conditions. Finally, a comparison between the experimental and the simulated measurements for the Ra, Rz and Rt was made, showing an increased correlation. Inderscience Publishers - linking academia, business and industry through research

Title: High-precision CAD-based simulation for turning considering tool microgeometry

Authors: Anastasios Tzotzis; Apostolos Tsagaris; Nikolaos Tapoglou; Panagiotis Kyratsis

Addresses: Department of Product and Systems Design Engineering, University of Western Macedonia, Kila Kozani, 50100, Greece ' Department of Industrial Engineering and Management, International Hellenic University, Sindos, Thessaloniki, 57400, Greece ' Department of Industrial Engineering and Management, International Hellenic University, Sindos, Thessaloniki, 57400, Greece ' Department of Product and Systems Design Engineering, University of Western Macedonia, Kila Kozani, 50100, Greece

Abstract: Surface roughness is considered to be a critical parameter when evaluating the machinability of a material, as well as the surface quality of a machined part. Thus, a number of studies exist in the literature, that deal with the simulation and prediction of the surface roughness generation during machining. This paper presents a 3D simulation method for turning, considering the full geometrical aspects of a cutting-tool, leading to highprecision simulation of the process. For the purposes of the study, a commercially available, generic CAD system was utilised, namely SolidWorks™. Specifically, the application programming interface (API) of the software was used, to write code that is capable of simulating the kinematics of the turning process. In addition, the surface roughness profile, topography, as well as typical measurements were generated, with respect to machining conditions such as, depth of cut, feed and cutting speed. For the verification of the accuracy of the code, a set of nine turning experiments were carried out, for a specified range of conditions. Finally, a comparison between the experimental and the simulated measurements for the R_a, R_z and R_t was made, showing an increased correlation.

Keywords: CAD-based simulation; API; application programming interface; surface roughness; surface topography; machining simulation; tool microgeometry; wiper nose.

DOI: 10.1504/IJMMS.2023.132023

International Journal of Mechatronics and Manufacturing Systems, 2023 Vol.16 No.1, pp.83 - 95

Received: 04 Dec 2022
Accepted: 29 Jan 2023
Published online: 06 Jul 2023 *

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Title: High-precision CAD-based simulation for turning considering tool microgeometry

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