Surface Topography Prediction Model for Free-form Surface Milling under a Dynamic System Response

Abstract

At present, numerous studies on surface topography prediction models for plane workpieces have been performed at home and abroad. Given the complexity of curved surface models (especially free-form surfaces that cannot be expressed in analytic formulas), prediction models for the surface topography of free-form surfaces are rarely studied. This paper aims to establish and simulate a 3D surface topography model of ball-end milling for all types of curved surfaces, including simple surfaces and free-form surfaces. The dynamic factors influencing the surface topography, such as the spindle runout initial phase angle, runout amplitude, axial drift initial phase angle, and axial drift amplitude are considered in this model. Moreover, some processing parameters influencing the surface topography, such as cutter tooth number, machining inclination, radial cutting depth, feeding frequency and feed per tooth are also considered in this model. The simulation results can be used to optimize the milling process of the actual free-form surface to improve workpiece surface quality or to predict the surface topography of the given machining parameters.