A roughness calculation method based on milling topography simulation

Abstract

The surface texture and roughness parameters of the workpiece after milling have a greater impact on the performance of the workpiece, so the analysis of the milling topography is particularly important. Firstly, the edge line of the ball end milling cutter was modeled. According to the movement law of the milling process, a complete set of milling topography simulation model was established, and a new influencing factor phase difference is proposed. In addition to the conventional cutting parameters, the model also considers the phase difference and tool inclination. Secondly, through the topography analysis and the calculation of the height of the convex peak Hmax, the comparison with the experiment was carried out to further verify the accuracy of the model. Finally, the point cloud data obtained from the topography simulation is processed, the roughness Sa is calculated according to the least square method. and the influence of the phase difference Δφ and the tool inclination β on the milling topography, surface texture and roughness Sa are respectively analyzed. The conclusions obtained provide guidance and reference for industrial parts designers who have specific texture requirements.

A Multi-Scale Tool Orientation Generation Method for Freeform Surface Machining with Bull-Nose Tool

“…When the inclination angle was between 0 and 60°, the roughness decreased first and then increased as the angle increased. Zhang et al [ 49 ] established a simulation model for ball-end tool milling to study the relationship between the inclination angle and roughness. The experimental results indicated that when the inclination angle increased from 0 to 30°, the roughness decreased first and then increased.…”