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Civil-Comp Proceedings
ISSN 1759-3433
CCP: 94
Edited by: B.H.V. Topping, J.M. Adam, F.J. Pallarés, R. Bru and M.L. Romero
Paper 17

GPGPU-based Material Removal Simulation and Cutting Force Estimation

B. Tukora1 and T. Szalay2

1Department of Information Technology, Pollack Mihály Faculty of Engineering, University of Pécs, Hungary
2Department of Manufacturing Science and Technology, Faculty of Mechanical Engineering, Budapest University of Technology and Economics, Hungary

Full Bibliographic Reference for this paper
B. Tukora, T. Szalay, "GPGPU-based Material Removal Simulation and Cutting Force Estimation", in B.H.V. Topping, J.M. Adam, F.J. Pallarés, R. Bru, M.L. Romero, (Editors), "Proceedings of the Seventh International Conference on Engineering Computational Technology", Civil-Comp Press, Stirlingshire, UK, Paper 17, 2010. doi:10.4203/ccp.94.17
Keywords: machining simulation, general-purpose graphics processing units, parallel computation, cutting force estimation.

The representatives of the newest generation graphics hardware are called general-purpose graphics processing units (GPGPUs), as they are suitable for executing non-graphical (e.g. general-purpose), massively parallelized computations besides the conventional graphical tasks. In 2008, at the University of Pécs, a research project started for exploiting the abilities of the new technology in case of machining simulations. The result of the first part of the work is a material removal simulation process, which is executed entirely by the graphics hardware, avoiding the slowing effect of CPU intervention and CPU-GPU data transfer.

The goal of the subsequent work has been to increase cutting force computation abilities. The applied multi dexel-based object representation allows accurate workpiece-tool touching area determination, which is the basis of the cutting force estimation. In this paper the adaptation of multi-dexel based material removal simulation and cutting force estimation using GPGPUs will be detailed. At first some features of the new generation GPUs will be described, which are indispensable for reaching our aims. This is followed by the short introduction to the selected volumetric method: the multi-dexel based one. Aspects of the selection will also be described. The main part of the paper details the process developed: the data conversion, simulation and visualization steps will be described, in which the multi-dexel volume is created from a boundary representation. The material removal simulation is processed by parallelized algorithms running on the GPU, and the altered volume of the work piece is visualized just after the dexels have been reconstructed to a displayable polyhedron structure. Finally the applied cutting force estimation method is described, which has been adapted to the multi dexel-based data format and the demands of the parallelized execution.

The paper also contains detailed performance and image quality tests, which verify the applicability of the process in the case of using middle- and high-performance graphics hardware.

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