Towards High-Fidelity Machining Simulation

The main purpose of any machining simulation system is to reveal or mimic the real machining process as accurately as possible. Current simulation systems often use C-code or CL data as input that has inherent drawbacks such as vendor-specific nature, incomplete data, irreversible data conversions and lack of accuracy. These limitations hinder the development of a truthful simulation system. Hence, there is a need for higher-level input data that can assist with accurate simulation for machining processes. In addition, there is also a need to take into account of true behaviour and real-time data of a machine tool. The paper presents a High-Fidelity Machining Simulation solution for more accurate results. STEP-NC is used as the input data as it provides a more complete data model for machining simulations. The status-quo of the machine tool is captured by means of sensors to provide true data values for machining simulation purposes. The outcome of the research provides a smart and better informed simulation environment. The paper reviewed some of the current simulation approaches, highlighted the current simulation problems, discussed input data sources for smart machining simulation and introduced the high-fidelity simulation system architecture. (C) 2011 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.