Integration of machining mechanistic models into CAM software

Due to the increasing requirements of 5-axis machined products, collision simulation is not enough to ensure final quality. Hence, machining simulation models have been developed and commercialized in the last years. Mechanistic (semiempirical) models give approximate estimations of cutting forces during a whole tool path and, even not being very accurate, they are very useful to detect critical tool path steps, adapt cutting parameters and avoid machine overload. The main problem of most of these models is the fact that they work isolated from CAM programs and so, all the required information must be manually imported and refreshed. This paper presents the integration of an open programmed mechanistic model into commercial CAM software. CAM simulates material removal process, while the model calculates and plots cutting efforts, and power. The whole simulation is performed into CAM environment and any kind of change in the process (tool, material, tool path, cutting speed, etc.) is automatically transferred to the mechanistic model. In the end, the user gets a CNC code that ensures not only collision avoidance, but also adequate process conditions.