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A novel simulation model of three-dimensional surface topography for five-axis CNC milling using bull-nose tool

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Abstract

Computer numerical control milling is a widely used method for machining free-form workpieces. Studies show that the surface topography of the workpiece has a significant correlation with its mechanical strength and dimensional accuracy. Furthermore, the surface topography is influenced by cutting parameters. The bull-nose tool, which adapts to curvature, is an affecting parameter in improving machining quality. In the present study, a novel three-dimensional surface topography simulation model was proposed. The model employs approximate surfaces to characterize the scallop, enabling analytical calculation of endpoints and boundaries for each scallop without the need to discretize the workpiece into 2D planes or an x–y grid. Subsequently, machining experiments were performed to validate the proposed simulation model. The results revealed that the proposed model could be used to effectively simulate surface topography and predict surface roughness. Finally, the effect of cutting parameters on surface topography and surface roughness was analyzed using the simulation model. And the recommendations were proposed for the selection of these cutting parameters. The developed model exhibits promising potential in engineering applications.

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Funding

This work received financial support from the National Natural Science Foundations of China (Grant Nos. 51775445 and 52175435), Defense Industrial Technology Development Program (No. XXXX2018213A001), and Key Research and Development Program of Shaanxi (Program Nos. 2016KTZDGY4-02 and 2019GY-064).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Jieshi Dong, Zhiyong Chang, Jinming He, Song Liu & Neng Wan

  2. Institute for Aero-Engine Smart Assembly of Shaanxi Province, Xi’an, 710072, Shaanxi, China

    Jieshi Dong, Zhiyong Chang, Jinming He, Song Liu & Neng Wan

Authors
  1. Jieshi Dong
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  2. Zhiyong Chang
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  3. Jinming He
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  4. Song Liu
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  5. Neng Wan
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Contributions

All authors contributed to design and implementation of the concept. Jieshi Dong: conceptualization, methodology, experimental design, writing—original draft preparation; Jinming He, Song Liu, and Neng Wan: investigation, experiment, data processing, and analysis; Zhiyong Chang: writing review and editing. All authors connected on previous versions of the manuscript and have read and approve the final manuscript.

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Correspondence to Zhiyong Chang.

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Dong, J., Chang, Z., He, J. et al. A novel simulation model of three-dimensional surface topography for five-axis CNC milling using bull-nose tool. Int J Adv Manuf Technol 128, 5041–5060 (2023). https://doi.org/10.1007/s00170-023-12239-7

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  • DOI: https://doi.org/10.1007/s00170-023-12239-7

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