Influence of Tool Assembly Error on Machined Surface in Peripheral Milling Process

Abstract

Simulation and prediction of the machining process and the machined results of milling process is an important link in the control of milling quality. It is important on improving the machined surface quality, improving processing efficiency, and reducing processing errors. In the milling process, the assembly error of the cutting tool has great importance that should not be ignored for the forming of milled surface. Aiming at the problem of machining error in milling process caused by tool assembly error, this article investigated the milling process of peripheral milling, and researched the surface topography caused by the tool assembly error. Then the author established a simulation model to forecast the processing error caused by peripheral milling cutter assembly error. The model calculates the location of the tooth tipoff the milling tool by analyzing the knife tooth trajectory variation caused by the tool assembly error. Then discrete tracks of the teeth, to obtain the final processed surface by calculating the minimum value of all the teeth traces at discrete points. Through this model, we can get different surface morphology formed by different tool assembly errors to explore how the tool assembly error influences the processing quality. The study shows that when the cutter assembly errors exist, each tooth tip trajectory changes, making the surface topography phenomena that surface rises and falls, and cutting grooves’ size shrinks and expands. Cutting groove depth will change in the direction of the tool axis direction. The surface roughness will increase when the cutter assembly error increases, but the roughness does not change after increasing to a threshold value.