New algorithm for the simulation of machined surface topography in end milling process

Simulating machined surface topography is critical since it directly affects the surface quality, especially the surface roughness. Based on the trajectory equation of the cutting edge relative to the workpiece and the geometrical characteristics of the end milling process, a method for predicting the topography of the generated surface is developed. With the method, it is unnecessary to discretize the cutting edge and mesh the workpiece, the topography values of any points on the surface on the workpiece can be calculated, and the cutter runout can be taken into account. The number of calculations is equal to the number of cutter teeth. The numerical results indicate that the algorithm is general, efficient and of high precision.