Turning and milling are the main manufacturing techniques in industry. A great deal of time and money is spent for machining operations. Although most of the time, the tool path of a CNC machine tool is generated by a Computer Aided Manufacturing (CAM) software package, to be sure that the result of the machining operation will be as required, it is necessary to use a simulation software. There are various machining simulation software packages available in the market. However, they are not only expensive, but also specialized for only one of the before mentioned machining techniques. Most of the companies in the industry are small or medium scale ones and, it is not so easy for them to afford a specialized simulation software for that purpose. In this thesis, it is aimed to develop a software package, which will be used to simulate advanced industrial machining processes, including turning and milling. Dexelmodeling, which is generated by ray casting, and sweep plane algorithm withpolygon clipping technique are used forvisualization. For polygon clipping technique, outer surfaces of the resultant workpiece are generated from planar contours. The software is developed in C# programming language and DirectX libraries are utilizedfor visualization purposes. With the aid of this software, it is also aimed to visually confirm the validity of both mill and lathe NC-code, by representing highly accurate 3D displayed results of these simulations.

The process of taking a solid model and producing a machined part requires the time and skillset of a range of professionals, and several hours of part review, process planning, and production. Much of this time is spent creating a methodical step-by-step process plan for creating the part from stock. The work presented here is part of a software package that performs automated process planning for a solid model. This software is capable of not only greatly decreasing the planning time for part production, but also give valuable feedback about the part to the designer, as a time and cost associated with manufacturing the part. In order to generate these parameters, we must simulate all aspects of creating the part. Presented here are models that replicate these aspects. For milling, an automatic tool selection method is presented. Given this tooling, another model uses specific information about the part to generate a tool path length. A machining simulation model calculates relevant parameters, and estimates a time for machining given the tool and tool path determined previously. This time value, along with the machining parameters, is used to estimate the wear to the tooling used in the process. Using the machining time and the tool wear a cost for the process can be determined. Other models capture the time of non-machining production times, and all times are combined with billing rates of machines and operators to present an overall cost for machining a feature on a part. If several such features are required to create the part, these models are applied to each feature, until a complete process plan has been created. Further post processing of the process plan is required. Using a list of available machines, this work considers creating the part on all machines, or any combination of these machines. Candidates for creating the part on specific machines are generated and filtered based on time and cost to keep only the best candidates. These candidates can be returned to the user, who can evaluate, and choose, one candidate. Results are presented for several example parts. / text

Made available in DSpace on 2016-12-12T17:38:34Z (GMT). No. of bitstreams: 1 Allan Yoshio Hasegawa.pdf: 18253702 bytes, checksum: e99aeb0d0d09ebc27b20111c88bac58f (MD5) Previous issue date: 2015-09-18 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / In this work were studied the main geometric representations in the context of machining simulations and its data structures. Several interactive rendering methods for complex model were studied as well. After the exploratory phase, a prototype simulator using Distance Fields and ray cast was developed. Tests were performed, concluding that the Distance Fields representation is suitable for machining simulation as it offers efficient Boolean operations, practical memory requirements and methods for interactive rendering of complex models with ray casting. / Neste trabalho foram estudadas as principais representações geométricas no contexto de simulações de usinagem e as estruturas de dados utilizadas por estas representações. Diversas técnicas de renderização interativa para modelos complexos foram exploradas. Após a fase exploratória, foi desenvolvido um protótipo de simulador usando Campos de Distância e ray casting. Testes foram executados, concluindo que Campos de Distância é uma representação adequada para simulações de usinagem, providenciando operações booleanas eficientes, consumo prático de memória e oferecendo uma visualização interativa de modelos complexos usando ray casting.