FusionCut: Boundary Representation (B-Rep) Based and Cloud-Ready Cutter Workpiece Engagement (CWE) for Virtual Machining

Abstract: Cutter-workpiece engagement (CWE) is the instantaneous contact geometry between the cutter and the in-process workpiece, playing a fundamental role in machining process simulation and directly affecting the prediction of cutting forces and process stability. The difficulty and challenge of CWE determination come from the complexity of continuously changing geometry, especially for multi-axis milling. To fulfill the requirement of generality -- for any cutter type, workpiece shape, or toolpath -- the research community has largely pursued two paths: geometrically exact solid modeling and approximate discrete modeling. The former, while accurate, has been hampered by reliance on proprietary, inaccessible software, hindering reproducibility and collaborative research. The latter sacrifices geometric fidelity for algorithmic generality, often leading to computational trade-offs. This paper presents a framework, FusionCut, that leverages the Boundary Representation (B-Rep) solid modeling kernel of an accessible, modern CAD/CAM platform Autodesk Fusion 360 -- as freely available for educational and non-commercial use. Our objective is to provide a reproducible framework for the B-Rep approach, while challenging the prevailing assumption that discrete methods such as the triangle meshes are required for general-purpose applications. By providing an accessible implementation and testing it with publicly available models and experiments, we aim to establish a baseline for what is computationally feasible and scientifically necessary for high-fidelity virtual machining. FusionCut offers a path to democratize advanced machining simulation, fostering a more open and progressive scientific ecosystem in digital manufacturing.