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<p>This paper presents a unified and efficient method for computing machined part geometry and cutter-workpiece engagement in general multi-axis milling. To accelerate the simulation process, the proposed method integrates a multi-level voxel update scheme with edge-surface intersection computation, which can be reused for workpiece surface reconstruction and further fused into the cutter-workpiece engagement region. By leveraging non-uniform spatial decomposition strategies, the proposed method enables batch processing of affected voxels and significantly reduces redundancy in intersection evaluation. It is implemented across six representative volumetric data structures to analyze their efficiency characteristics, providing actionable guidance for selecting optimal configurations under different simulation requirements. Extensive evaluations on practical five-axis milling cases clearly demonstrate that the proposed approach achieves satisfactory modeling accuracy and significantly higher computational efficiency than the traditional tri-dexel model at equivalent grid resolution. The method supports arbitrary cutter geometries, complex tool paths, and varying resolution demands, offering a practical and generalizable modeling strategy for high-resolution virtual machining, with strong potential for integration into advanced multi-axis NC simulation workflows.</p>

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Comparison of six voxel-based data structures via a unified multi-axis milling simulation framework

  • 期刊论文

  • 发表日期：

    2025年8月16日

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  • Zhengwen Nie,
  • Jiabin Cao,
  • Yiyang Zhao,
  • Lin Zhang,
  • Xun Liu,
  • Yan Xu,
  • Yanzheng Zhao

摘要

This paper presents a unified and efficient method for computing machined part geometry and cutter-workpiece engagement in general multi-axis milling. To accelerate the simulation process, the proposed method integrates a multi-level voxel update scheme with edge-surface intersection computation, which can be reused for workpiece surface reconstruction and further fused into the cutter-workpiece engagement region. By leveraging non-uniform spatial decomposition strategies, the proposed method enables batch processing of affected voxels and significantly reduces redundancy in intersection evaluation. It is implemented across six representative volumetric data structures to analyze their efficiency characteristics, providing actionable guidance for selecting optimal configurations under different simulation requirements. Extensive evaluations on practical five-axis milling cases clearly demonstrate that the proposed approach achieves satisfactory modeling accuracy and significantly higher computational efficiency than the traditional tri-dexel model at equivalent grid resolution. The method supports arbitrary cutter geometries, complex tool paths, and varying resolution demands, offering a practical and generalizable modeling strategy for high-resolution virtual machining, with strong potential for integration into advanced multi-axis NC simulation workflows.