Unified 2D polygon-based CAM framework integrating tool path generation, machinability evaluation, and cutting-force simulation

This study proposes a unified two-dimensional (2D) polygon-based computer-aided manufacturing (CAM) framework that enables tool path generation, machinability evaluation, material removal simulation, and cutting-force prediction within a single computational environment. The proposed method represents three-dimensional geometries as aggregates of orthogonal 2D polygon sets, obtained by slicing the model in the xy-, yz-, and zx-parallel planes and superposing the three polygonal datasets. A novel convolutional offsetting algorithm is developed to perform three-dimensional inflation and shrinkage by incorporating adjacent cross-sectional relationships, thereby achieving accurate 3D offsets independent of the slicing orientation. The inflated 2D polygons are directly utilized to generate contour and scanning tool paths, and sequential inflation–shrinkage analysis enables visualization of unmachinable regions for tool accessibility evaluation. Furthermore, the framework integrates an instantaneous cutting force model that accurately predicts the cutting force waveform by detecting intersections between the cutting edge points and 2D polygon aggregations. The system is experimentally validated via ball-end milling. The results demonstrate that tool paths can be generated in under one minute using only a CPU. Furthermore, the simulated cutting forces closely align with experimental measurements. These findings demonstrate that the proposed 2D polygon-based framework provides an efficient and extensible foundation for integrating mechanical simulation and tool-path generation.