Prediction of plastic surface defects for 5-axis ball end milling of Ti-6Al-4 V with rounded cutting edges using a material removal simulation

Abstract

The resulting surface quality after 5-axis ball end milling is of superior importance because finish milling is often the last process step determining the functional performance of a component. However, the prediction of surface topography is still a challenging task. Especially in ball end milling with the characteristic sickle shaped chip cross section, ploughing effects in the area of low chip thickness result in plastic deformation and surface defects (also known as burr). This paper provides a new approach to predict those surface defects by considering the minimum chip thickness for complex milling engagement conditions within a virtual process design. This allows the choice of suitable process parameters without extensive experimental efforts.