A new mathematical method of modeling parts in virtual CNC lathing and its application on accurate tool path generation

In industry, many taper shafts are designed with tolerances of a few microns. To cut them in finish turning, paths of the tool in virtual machining should be accurately generated beforehand. For this purpose, the dimension errors and surface roughness of the virtually cut workpiece should be predicted. Unfortunately, the current tool path generation methods cannot accurately calculate the errors and the roughness, resulting in the taper errors larger than the part tolerance. Our research formulates equations of the effective turning edge to accurately calculate the dimension errors and the surface roughness, and then proposes a new approach to CNC programming for high-precision CNC turning. It lays a theoretical foundation of modeling parts in virtual turning and can generate tool paths to machine taper parts with high accuracy.