Abstract
This paper presents an analytical simulation method to estimate a machine profile in spherical milling with a ball-nosed spiral cutting edge tool. The height of machined profile is regarded as the cross point of the moving cutting edge and a specified normal line. The geometric equations determining the rotating angle of the tool and the cross point were formulated and solved originally in numerical calculations of Newton-Raphson method. The phase difference angle of the spiral cutting edge was measured and embedded into the formula. By developing the faster method to get the initial solution of the numerical calculations, a graphic simulation of the machined surface can be displayed three times faster than that in a case of a flat cutting edge. Also the discriminant of the interference between the flank of the tool and the machined surface has been formulated and introduced into the simulation method. Then the exact profile of machined surface could be estimated by the presented method. Through the formula development and graphic simulation, the landscape features of machined surface have been well recognized and the cusp height could be exactly estimated. Experimental simulations have been illustrated and the conclusions are described briefly.
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