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Modelling and prediction of surface topography on machined slot side wall with single-pass end milling

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Abstract

The previous research on machined surface topography in milling processes usually focuses on simple and single machining features such as free flat and form surfaces. However, the industrial components are composed of complex machining features such as slots and grooves finished by profile milling cutters. The formation mechanism and prediction method of machined surface topography for the complex milling features are required in industrial applications. Firstly, the machined side surface topography formation mechanism in profile milling straight slot machined by single-pass processing with a solid end mill is presented. Then, the numerical prediction models for machined side surface roughness in straight slot profile end milling are proposed. The proposed model can accurately predict the surface topography, and the relative prediction errors of the surface roughness (Sa) are within 6.34% for the whole cases in this research. Finally, the effect of cutting parameters on the residual heights of the machined side surface is analyzed. The formation mechanisms of machined two side surface topographies on the straight slot are distinct, for which one side surface is machined by up milling while another is by down milling. It is shown that the different tool trajectories cause the distinction for milling each slot side. The machined side surface topography can be controlled by selecting optimized tool motion parameters and cutting parameters. The influences of tool deflection and tool wear on the surface topography are ignored in the current research, which will be considered in the future.

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Funding

This work received financial support from the National Key Research and Development Program of China (2019YFB2005401). This work was also supported by grants from the National Natural Science Foundation of China (No. 91860207), Shandong Provincial Key Research and Development Program (Major Scientific and Technological Innovation Project, No. 2020CXGC010204), and Taishan Scholar Foundation.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jingshi Road 17923, Jinan, 250061, People’s Republic of China

    Wenjun Lyu, Zhanqiang Liu, Qinghua Song, Xiaoping Ren, Bing Wang & Yukui Cai

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE/Key National Demonstration Center for Experimental Mechanical Engineering Education, Jinan, 250061, People’s Republic of China

    Wenjun Lyu, Zhanqiang Liu, Qinghua Song, Xiaoping Ren, Bing Wang & Yukui Cai

Authors
  1. Wenjun Lyu
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  2. Zhanqiang Liu
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  3. Qinghua Song
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  4. Xiaoping Ren
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  5. Bing Wang
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  6. Yukui Cai
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Contributions

Wenjun Lyu: investigation, conceptualization, writing—original draft. Zhanqiang Liu: writing—review and editing, methodology, validation, resources, data curation, supervision, project administration, funding acquisition. Qinghua Song: writing—review and editing. Xiaoping Ren: validation. Bing Wang: analysis, suggestion, and discussion. Yukui Cai: formal analysis.

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Correspondence to Zhanqiang Liu.

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Lyu, W., Liu, Z., Song, Q. et al. Modelling and prediction of surface topography on machined slot side wall with single-pass end milling. Int J Adv Manuf Technol 124, 1095–1113 (2023). https://doi.org/10.1007/s00170-022-10587-4

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