A new algorithm for the numerical simulation of machined surface topography in multiaxis ball-end milling

Wei Hong Zhang, Gang Tan, Min Wan, Tong Gao, David Hicham Bassir

Research output: Contribution to journalArticlepeer-review

53 Scopus citations

Abstract

In milling process, surface topography is a significant factor that affects directly the surface integrity and constitutes a supplement to the form error associated with the workpiece deformation. Based on the tool machining paths and the trajectory equation of the cutting edge relative to the workpiece, a new and general iterative algorithm is developed here for the numerical simulation of the machined surface topography in multiaxis ball-end milling. The influences of machining parameters such as the milling modes, cutter runout, cutter inclination direction, and inclination angle upon the topography and surface roughness values are studied in detail. Compared with existing methods, the basic advantages and novelties of the proposed method can be resumed below. First, it is unnecessary to discretize the cutting edge and tool feed motion and rotation motion. Second, influences of cutting modes and cutter inclinations are studied systematically and explicitly for the first time. The generality of the algorithm makes it possible to calculate the pointwise topography value on any sculptured surface of the workpiece. Besides, the proposed method is proved to be more efficient in saving computing time than the time step method that is commonly used. Finally, some examples are presented and simulation results are compared with experimental ones.

Original languageEnglish
Pages (from-to)110031-1100311
Number of pages990281
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume130
Issue number1
DOIs
StatePublished - Feb 2008

Keywords

  • Ball-end milling
  • Sculptured surface
  • Simulation algorithm
  • Surface topography

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