Numerical Simulation of Machined Surface Topography and Roughness in Milling Process

Abstract

Machined surface topography is very critical since it directly affects the surface quality, especially the surface roughness. Based on the trajectory equations of the cutting edge relative to the workpiece, a new method is developed for the prediction of machined surface topography. This method has the advantage of simplicity and is a mesh-independent direct computing method over the traditional interpolation scheme. It is unnecessary to discretize the cutting edge or to mesh the workpiece. The topography value of any point on the machined surface can be calculated directly, and the spindle runout can be taken into account. The simulation of machined surface topography is successfully carried out for both end and ball-end milling processes. In the end milling process, a fast convergence of solving the trajectory equation system by the Newton-Raphson method can be ensured for topography simulation at any node on the machined surface thanks to the appropriate choice of the starting point. In the ball-end milling process, this general algorithm is applicable to any machined surface. Finally, the validity of the method is demonstrated by several simulation examples. Simulation results are compared to experimental ones, and a good agreement is obtained.

Model for the prediction of 3D surface topography in 5-axis milling

“…Starting from the expression of the trajectory equation of the cutting edge relative to the workpiece and the tool paths, Zhang et al introduced a new and general iterative method to simulate roughness in multi-axis ball-end milling [24] [25]. This method has the advantage of simplicity and is a mesh-independent direct computing method.…”

The effect of tool vibrations on the flank surface created by peripheral milling

“…For finishing processes of parts which demand a high quality with respect to surface accuracy or roughness, the aim is more specific; that is, to maximize the removal rate and to keep the surface location error as low as possible. A simulation system for the optimization of finishing processes not only has to predict stability boundaries, but also the probable surface location error, roughness and formation [5][6][7][8].…”

Modelling and Visualization of the Surface Resulting from the Milling Process

“…In contrast to the work of Gao et al (2006); Li & Shin (2006); Omar et al (2007), where the surfaces are modelled as a high resolved continous triangulation, in this work a simpler way is presented which generates a point-based surface model which is capable of rendering the surface of complex parts generated by NC-milling processes.…”