A divide and conquer approach for machined surface topography reconstruction in peripheral milling inconel 718

Abstract

This paper proposes a reconstruction procedure to characterize the texture of milled surfaces following the principle of a divide and conquer algorithm. It is a combination of a numerical simulation of the systematic component of the surface topography with the stochastic features of surface roughness. Firstly, the milled surface topographies are decomposed into kinematic and random components, both of them are calculated separately. Then, the kinematic components are numerically simulated based on relative motion between milling tool and workpiece. The random components are numerically simulated by fast Fourier transform (FFT) and the Johnson transform system. The measured and kinematic topographies are aligned fitting orientation and position by point clouds registration. Finally, the milled surface topographies are reconstructed by superposition of kinematic and random components based on the alignment datum. The proposed approach is applied to surface topography simulation and surface roughness prediction in peripheral milling Inconel 718. The milled surface topographies can be simulated by using the milling parameters as input parameters of the proposed model. The validation tests were carried out in Inconel 718 peripheral milling. The results show that the proposed approach has high accuracy in topography simulation and roughness prediction. The relative errors of predicted S a values are less than 7.55% in all the case studies of this paper. The effect of cutting parameters on roughness S a is sorted as follows, radial cutting depth > cutting speed > feed rate. In addition, the feed rate greater than 0.01 mm tooth−1 should be selected as far as possible in milling Inconel 718.