Abstract
Advances in computer technology have made possible the integration of complex geometric and process modeling capabilities for use in engineering design and process planning. This is evident in the area of machining where it is now possible to integrate the physics of the machining process with changes that are taking place to the geometry of a work piece during the execution of complex operations. This capability is referred to as Virtual Machining (VM). Geometric modeling capabilities include the ability to generate complex swept volumes created during execution of tool path moves, to subtract these from a dynamically changing in-process work piece model, and to extract the instantaneous cutter/workpiece engagement as the tool moves in the feed direction. Process modeling includes the use of this engagement geometry to calculate cutting forces, deflection of structures, vibrations and to use these in process optimization. This paper reviews advances in the first part of this tandem, the geometric modeling methods and techniques that make Virtual Machining possible. It further highlights important directions that can be taken to further advances in this field.