Simultaneous prediction of surface topography and surface location error in milling

Abstract

The machined surface topography, surface roughness and surface location error are very important evaluation indexes for machining quality, which directly affect the performance characteristics of the machined workpiece. In this paper, a new model of the arbitrary point of the cutter edge with respect to the arbitrary frame of the machining feature point is built. The proposed model incorporates the surface location error into the relative motion of the cutter with respect to the workpiece using the harmonic balance methods. Further, a nonlinear programming problem is proposed to obtain the scallop value of an arbitrary point on the nominal machined surface. Since the obtained scallop value of each point can be used for constructing the topography of the machined surface as well as calculating the surface roughness, the proposed model can simultaneously predict the surface topography, surface roughness and surface location error.Simulations and experiments indicate that feed per tooth, runout and number of cutter teeth are vital factors influencing the topology of the machined surface. The surface location error of the cutter due to the number of cutter teeth is an essential factor that influences the parallelism or perpendicularity of the machining feature. The effectiveness and feasibility of the proposed method is verified by a machining example.

Extended classification of surface errors shapes in peripheral end-milling operations

“…(11) (12) The accuracy of these expressions (11,12) is related to the accuracy of the cutting model considered; nonetheless, the use of these expressions can be extended to more complex cutting models. To fully describe the effects of ar and ap on the F y shape, an additional radial engagement angle α enu is defined for up-milling (13). (13) α enu represents the radial engagement angle which fixes the angular position of the peak value of F y , and it depends on how F t and F r combine along the y-direction in the final instants of the cut.…”

“…tool deflection [10,11]). Dynamic mechanisms impact on the machined surface mostly at the roughness level [12], instead static mechanisms affect the ma-chined surface mainly at the form level [13]. Most of the works on this topic are focused on error prediction, often using numerical methods [14], while few [15][16][17] are dedicated to investigating and classifying the error shapes assumed by surface at different cutting conditions.…”

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

“…The effect of machining parameters such as cutting speed, depth of cutting, feed rate of each tooth, number of cutting edges, run out and tool geometry on surface quality 28 and on the stability of milling process have already been considered by researchers. In this regard, Sims and Jin et al 29,30 investigated the effect of using cutting tools with variable helix angles on the prevention of chatter vibrations during milling operation.…”

Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter

“…Schmitz and colleagues 21,22 gave out a closed-form solution for cutter displacement response and pointed out that the cutter runout would affect the roughness and surface location error. Yuan et al 23 analyzed the surface topography and surface location error based on the harmonic balance method, in which the influence of feed per tooth, runout and number of cutter teeth on topography was discussed. Denkena et al 24 reconstructed the cutter actual motion and extracted the form surface morphology based on the measured milling force data and the frequency coupling dynamic model of tool system.…”