Two-Dimensional Profile Simulation Model for Five-Axis CNC Machining with Bull-Nose Cutter

Surface topography is closely related to fatigue strength and mating accuracy of workpieces. The profile method is widely adopted to evaluate surface topography. In the present study, a 2D profile simulation model of five-axis CNC machining with a bull-nose cutter is proposed to predict the surface topography of a machined workpiece. To this end, a simplified scallop model is established by analyzing the geometry and motion of the bull-nose cutter. Then, the principles of the 2D profile simulation model for plane and free-form surfaces are described to provide the basis for building 2D profile simulation models. After that, 2D profiles are obtained directly from CL data, tool parameters, and workpiece design models, and an algorithm is proposed to obtain 2D profiles. Finally, the proposed algorithm is verified by different machining experiments on plane and free-form surfaces. The results show that the simulation and measurement results are in good agreement. The proposed simulation model for five-axis CNC machining with a bull-nose cutter can be effectively applied to simulate 2D profiles of plane and free-form surfaces. The present study is expected to provide a reference for optimizing process parameters.