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TECHNICAL PAPERS

Numerical Simulation of Machined Surface Topography and Roughness in Milling Process

[+] Author and Article Information
Tong Gao, Kepeng Qiu, Min Wan

The Key Laboratory of Contemporary Design & Integrated Manufacturing Technology, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China

Weihong Zhang1

The Key Laboratory of Contemporary Design & Integrated Manufacturing Technology, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 128(1), 96-103 (Mar 15, 2005) (8 pages) doi:10.1115/1.2123047 History: Received June 08, 2004; Revised March 15, 2005

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.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Coordinate systems in the milling process

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Figure 2

Coordinate systems in the end milling process

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Figure 3

Trajectory of the point on the jth cutting edge

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Figure 4

Coordinate systems in the ball-end milling process

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Figure 5

Curves of equation system without spindle runout (e=0)

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Figure 6

Relationship between θ and p

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Figure 12

Simulation results in ball-end milling process: (a) simulation model; (b) α=30deg, κ=0deg, Ra=2.395μm; (c) α=30deg, κ=45deg, Ra=2.328μm; (d) α=60deg, κ=0deg, Ra=2.421μm

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Figure 13

Effects of the cross feed on the surface roughness in the ball-end milling process

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Figure 14

Effects of the cutter radius on the surface roughness in the ball-end milling process

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Figure 11

Effects of the feed speed on the surface roughness in the end milling process

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Figure 10

Effects of the cutter radius on the surface roughness in the end milling process

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Figure 9

Comparison of the profile between simulation and experimental results

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Figure 8

Simulation results in the end milling process: (a) up milling and (b) down milling

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Figure 7

Convergence curves of the iteration process: (a) convergence curves of x and y, and (b) convergence curves of θ and t

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