Abstract
In this work, a theoretical analysis of surface generation numerical model is presented to predict the surface roughness achieved by side milling operations with cylindrical tools. This work is focused on the trajectory of tools with two teeth by the influence of tool errors such as radial runouts, as well as straightness with dynamic effects. A computational system was developed to simulate roughness topography in contour milling with cylindrical tool. Finally, the PSO (particle swarm optimization) algorithm is employed to find the optimal machining position for the best surface roughness. Experimental data is satisfied with the novel protection model for the tooth’s trajectory, and the final prediction accuracy is high enough, i.e. that the prediction surface roughness. Low prediction surface roughness error (1.37~15.04%) and position error (0.95~1.25 mm) indicate effectiveness of the model built in this work. The novel model may be used to determine the variation in surface roughness.
Highlights
During the incoming years, side milling technology with high feed speed would be widely used in moulds and machined parts processing, especifically in vertical walls of contours
Tool runout errors Measured standard deviation εY and εX of radii runout values of tool used in experiments was 1 μm and 0.8 μm
The straightness error is random and difficult to describe as a function, and different machining locations have different effects on surface roughness
Summary
Side milling technology with high feed speed would be widely used in moulds and machined parts processing, especifically in vertical walls of contours. Surface roughness is one of great importance for the performance of surface quality [3], which is mainly evaluated by Ra (average roughness) and Rz (peaks and valleys) It depends partly on the cutting conditions (especially feed per tooth), and partly on the tool (the factors which lead to differences in the cutting edge radii) and on the machine, such as runout, eccentricity or parallel axis offset and axis inclination (tilt angle) [4,5]. The sampling length Average roughness Peaks and valleys (h) Radial depth of cut Spindle speed Feed speed The tool radius Feed per tooth Maximum undeformed chip thickness Angle of teeth Number of teeth Radial runout Axial runout The straightness of Y in X direction Distance from processing position
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