8306

Material Removal Simulation and Cutting Force Prediction of Multi-Axis Machining Processes on General-Purpose Graphics Processing Units

Balazs Tukora
Department of Manufacturing Science and Engineering, Faculty of Mechanical Engineering, Budapest University of Technology and Economics
@article{szalay2012material,

   title={Material Removal Simulation and Cutting Force Prediction of Multi-Axis Machining Processes on General-Purpose Graphics Processing Units},

   author={SZALAY, T.},

   year={2012}

}

Download Download (PDF)   View View   Source Source   

663

views

The efficient planning of automated machining processes is unthinkable without the use of offline CAM systems. Though machining programs can be written and input manually, right at the machine controller, if the workpiece geometry is complex, or if the machined features are numerous, the help of CAM software is essential for generating the program both accurately and quickly. This is particularly true in the case of multi-axis machining, when complex, often sculpture-like shapes are machined in a single set-up. The determination of the optimal toolpath in accordance with the CAD part designs requires sophisticated computerized algorithms. On the other hand, it is indispensable to allow the user to verify and – if it’s needed – manually modify the computer-generated operations in the course of the interactive planning process. The most evident mode of the verification is the ocular inspection of the planned machining operations on the screen of the CAM software. The visual representation of the machining processes has several levels, from the simple linear drawing of the toolpath until the detailed displaying of the altering workpiece geometry during the material removal process. While the first helps shifting out the rough errors of the automated toolpath generation, the latter can bring the unwanted geometrical errors of the machined part to light. The first part of the dissertation deals with this higher level of machining process representation. The simulation of the material removal process presents a special challenge for the CAM software developers. To get the final shape of the workpiece the simulation of the whole material removal process has to be fulfilled. Considering that the resolution of the displayed objects must satisfy the requirements of the visual verification, a huge amount of data, which carries enough geometrical information for the detailed description, has to be processed within a short time. In the course of time several simulation methods have come to life to perform this task, with various levels of performance. One of the oldest, and still the most effective solution up to now exploited that the operations of the material removal can be performed in a highly parallelized thus effective manner by the use of graphics processing units (GPU). Unfortunately this method proved to be viable only in the simple geometrical circumstances of 3-axis machining. The complex geometry of a workpiece that is shaped during multi-axis machining cannot be represented with data structures used by the traditional GPUs, and the sequential execution by the CPU cannot even approach the performance of the GPU based solution.
VN:F [1.9.22_1171]
Rating: 0.0/5 (0 votes cast)

* * *

* * *

Like us on Facebook

HGPU group

125 people like HGPU on Facebook

Follow us on Twitter

HGPU group

1181 peoples are following HGPU @twitter

* * *

Free GPU computing nodes at hgpu.org

Registered users can now run their OpenCL application at hgpu.org. We provide 1 minute of computer time per each run on two nodes with two AMD and one nVidia graphics processing units, correspondingly. There are no restrictions on the number of starts.

The platforms are

Node 1
  • GPU device 0: AMD/ATI Radeon HD 5870 2GB, 850MHz
  • GPU device 1: AMD/ATI Radeon HD 6970 2GB, 880MHz
  • CPU: AMD Phenom II X6 @ 2.8GHz 1055T
  • RAM: 12GB
  • OS: OpenSUSE 13.1
  • SDK: AMD APP SDK 2.9
Node 2
  • GPU device 0: AMD/ATI Radeon HD 7970 3GB, 1000MHz
  • GPU device 1: nVidia GeForce GTX 560 Ti 2GB, 822MHz
  • CPU: Intel Core i7-2600 @ 3.4GHz
  • RAM: 16GB
  • OS: OpenSUSE 12.2
  • SDK: nVidia CUDA Toolkit 6.0.1, AMD APP SDK 2.9

Completed OpenCL project should be uploaded via User dashboard (see instructions and example there), compilation and execution terminal output logs will be provided to the user.

The information send to hgpu.org will be treated according to our Privacy Policy

HGPU group © 2010-2014 hgpu.org

All rights belong to the respective authors

Contact us: