Quadtree-array-based workpiece geometric representation on three-axis milling process simulation

A workpiece hybrid representation method based on quadtree-array is presented to improve the geometric simulation efficiency on three-axis milling process. The method takes the advantages both of Z-Map and quadtree in simulation model representation. The discrete points managed by using Z-Map algorithm is to represent the whole model, while the points used to represent the simulated surface detail are managed with quadtree-array. The method can reduce the levels of a quadtree without losing simulation accuracy. A dynamic optimization algorithm to the quadtree structure is highlighted to reduce its total nodes in simulation process. As a result, the simulation efficiency can be improved significantly. A three-axis milling process simulation system based on quadtree-array representation was developed and used to evaluate the performance of the presented method. The evaluated results show that quadtree-array-based hybrid representation method of workpiece can improve the simulation efficiency significantly, and reasonable division number of array cells is also recommended.