Simulation of surface roughness and profile in high-speed end milling

Abstract

As more emphasis is placed on quality and productivity in manufacturing, high-speed end milling has been studied recently. Although high-speed end milling is explicitly effective for precise surface generation geometrically, the vibration that is caused by the high speed of the spindle deteriorates the geometric accuracy of the machined surface. Many simulation algorithms have been introduced to predict the machined surface in end milling. These algorithms are almost all based on cutting force models. In normal-speed end milling, these models are relatively effective for the simulation of the machined surface, but in high-speed end milling these models have no consideration for the vibration of the spindle system. In this study, a simulation algorithm and programming method are suggested to simulate the machined surface using acceleration signal in high-speed end milling. The simulated results are compared with measured results from which it is considered that the suggested algorithm gives good simulated results.