Skip to main content
SpringerLink
Log in

Swept surface-based approach to simulating surface topography in ball-end CNC milling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The parts, in automotive, aerospace, die/mold industry, which have extremely high demands on the quality and integrity of the surface, are usually milled by CNC machine tools. In order to obtain the desirable surface quality, it is an effective way to choose the appropriate cutting parameters before machining by simulating the surface topography formed in the milling process. To do so, this paper develops a model based on the swept surface of the cutting edge and N-buffer model for predicting the surface topography and studies the effect of various cutting parameters. In this developed model, the mathematical equation of the cutting edge is first given, and then based on the relative motion between the cutter and the workpiece, the swept surface of the cutting edge along the tool path is accurately analyzed and modeled from the perspective of kinematics, which is used to describe realistically the cutting interaction between the cutter and the workpiece. Subsequently, the milling process is simulated by an improved N-buffer model by means of the proposed accurate interpolation method for calculating the cusp height. This procedure presents the advantage of not requiring any numerical iteration or approximation to gain the cusp height of any point on workpiece. On basis of the model, the effect of the cutting parameters such as spindle speed, feedrate, inclination angle, path interval, and cutter runout is investigated. Finally, the real machining experiments are performed and compared with the predicted results. The simulated surface topography shows a good agreement with the experimental one. This demonstrates that the developed model can predict accurately the surface topography and also provide the great potential for the surface quality control and the cutting parameter selection in actual production.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Liu N, Wang SB, Zhang YF, Lu WF (2016) A novel approach to predicet surface roughness based on specific cutting energy consumption when slot milling Al-7075. Int J Mech Sci 118:13–20

    Article  Google Scholar 

  2. Zhang C, Guo S, Zhang HY, Zhou LS (2013) Modeling and predicting for surface topography considering tool wear in milling process. Int J Adv Manuf Technol 68:2849–2860

    Article  Google Scholar 

  3. Raja SB, Baskar N (2012) Application of particle swarm optimization technique for achieving desired milled surface roughness in minimum machining time. Exp Syst App 39(5):5982–5989

    Article  Google Scholar 

  4. Chung YC, Park JW, Shin H, Choi BK (1998) Modeling the surface swept by a generalized cutter for NC verification. Comput Aided Des 30(8):584–587

    Article  MATH  Google Scholar 

  5. Feng HS, Li HW (2002) Constant scallop-height tool path generation for three-axis sculptured surface machining. Comput Aided Des 34(9):647–654

    Article  Google Scholar 

  6. Kim BH, Chu CN (1999) Texture prediction of milled surfaces using texture superposition method. Comput Aided Des 31(8):485–494

    Article  MATH  Google Scholar 

  7. Ryu SH, Choi DK, Chu CN (2006) Roughness and texture generation on end milled surfaces. Int J Mach Tools Manuf 46(3):404–412

    Article  Google Scholar 

  8. Jung TS, Yang MY, Lee KJ (2005) A new approach to analysing machined surfaces by ball-end milling, part I: formulation of characteristic lines of cut remainder. Int J Adv Manuf Technol 25(9–10):833–840

    Article  Google Scholar 

  9. Jung TS, Yang MY, Lee KJ (2005) A new approach to analysing machined surfaces by ball-end milling, part II: roughness prediction and experimental verification. Int J Adv Manuf Technol 25(9–10):841–849

    Article  Google Scholar 

  10. Liu X, Soshi M, Sahasrabudhe A, Yamazaki K, Mori M (2006) A geometrical simulation system of ball end finish milling process and its application for the prediction of surface micro features. ASME Trans, J Manuf Sci Eng 128(1):74–85

    Article  Google Scholar 

  11. Liu N, Loftus M, Whitten A (2005) Surface finish visualisation in high speed, ball nose milling applications. Int J Mach Tools Manuf 45(10):1152–1161

    Article  Google Scholar 

  12. Antoniadis A, Savakis C, Bilalis N, Balouktsis A (2003) Prediction of surface topomorphy and roughness in ball-end milling. Int J Adv Manuf Technol 21(12):965–971

    Article  Google Scholar 

  13. Buj-Corral I, Vivancos-Calvet J, Domínguez-Fernández A (2012) Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut. Int J Mach Tools Manuf 53(1):151–159

    Article  Google Scholar 

  14. Bouzakis KD, Aichouh P, Efstathiou K (2003) Determination of the chip geometry, cutting force and roughness in free form surfaces finishing milling, with ball end tools. Int J Mach Tools Manuf 43(5):499–514

    Article  Google Scholar 

  15. Omar OEEK, El-Wardany T, Ng E, Elbestawi MA (2007) An improved cutting force and surface topography prediction model in end milling. Int J Mach Tools Manuf 47(7):1263–1275

    Article  Google Scholar 

  16. Zhang C, Zhang H, Li Y, Zhou L (2015) Modeling and on-line simulation of surface topography considering tool wear in multi-axis milling process. Int J Adv Manuf Technol 77(1–4):735–749

    Article  Google Scholar 

  17. Arizmendi M, Fernández J, de Lacalle LL, Lamikiz A, Gil A, Sánchez JA, Campa FJ, Veiga F (2008) Model development for the prediction of surface topography generated by ball-end mills taking into account the tool parallel axis offset. Experimental validation. CIRP Annals-Manuf Technol 57(1):101–104

    Article  Google Scholar 

  18. Chen JS, Huang YK, Chen MS (2005) A study of the surface scallop generating mechanism in the ball-end milling process. Int J Mach Tools Manuf 45(9):1077–1084

    Article  Google Scholar 

  19. Zhang WH, Tan G, Wan M, Gao T, Bassir DH (2008) A new algorithm for the numerical simulation of machined surface topography in multiaxis ball-end milling. ASME Trans, J Manuf Sci Eng 130(1):011003

    Article  Google Scholar 

  20. Quinsat Y, Sabourin L, Lartigue C (2008) Surface topography in ball end milling process: description of a 3D surface roughness parameter. J Mater Process Technol 195(1):135–143

    Article  Google Scholar 

  21. Lavernhe S, Quinsat Y, Lartigue C (2010) Model for the prediction of 3D surface topography in 5-axis milling. Int J Adv Manuf Technol 51(9–12):915–924

    Article  Google Scholar 

  22. Quinsat Y, Lavernhe S, Lartigue C (2011) Characterization of 3D surface topography in 5-axis milling. Wear 271(3):590–595

    Article  Google Scholar 

  23. Mizugaki Y, Hao M, Kikkawa K, Nakagawa T (2001) Geometric generating mechanism of machined surface by ball-nosed end milling. CIRP Annals-Manuf Technol 50(1):69–72

    Article  Google Scholar 

  24. Li ZL, Zhu LM (2014) Envelope surface modeling and tool path optimization for five-axis flank milling considering cutter runout. ASME Trans, J Manuf Sci Eng 136:41021

    Article  Google Scholar 

  25. Schneider PJ, Eberly DH (2005) Geometric tool for computer graphics (in Chinese and translated by Zhou CF). Publishing House of Electronics Industry, Beijing

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Automotive Engineering, Dalian University of Technology, Dalian, 116024, People’s Republic of China

    Jinting Xu & Hai Zhang

  2. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, People’s Republic of China

    Yuwen Sun

Authors
  1. Jinting Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hai Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yuwen Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jinting Xu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xu, J., Zhang, H. & Sun, Y. Swept surface-based approach to simulating surface topography in ball-end CNC milling. Int J Adv Manuf Technol 98, 107–118 (2018). https://doi.org/10.1007/s00170-017-0322-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0322-1

Keywords

Search

Navigation