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3D bevel surface topography analysis and roughness prediction by considering the cutter-workpiece dynamic interaction

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Abstract

Surface roughness with topography modeling is one of the most important indicator for evaluating the surface quality in the machining process. This paper establishes a 3D surface roughness prediction model for bevel milling by considering the factors such as milling geometry, motion trajectory, and elastic-plastic deformation. Most of the existing roughness prediction models for bevel milling are based on regression models combined with multiple methods, which makes these models cannot well applied in complicated applications. Aiming at the change of contact area between tool and workpiece in bevel milling, the concept of effective cutting edge is introduced to establish a surface topography simulation model. Furthermore, this model fully considered the milling method, machine perpendicularity, and elastic-plastic deformation. Combined with the international standard of three-dimensional surface roughness, the roughness is predicted according to the residual height of each point on the surface topography. In order to verify the model accuracy and to explore the influence of process parameters on roughness and milling force in bevel and plane milling, two orthogonal experiments are designed in this paper. The experimental results show that the surface topography simulation results are consistent with the actual shape characteristics. The average relative error of roughness prediction is 7.93%, and the minimum is only 0.84%. In addition, the experimental results show that the two factors that have a great influence on the roughness are the spindle speed and feed rate, while the cutting depth and step distance greatly impact on the milling force.

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Funding

This work is supported in by the Fundamental Research Funds for the Central Universities (2232023D-15), the China Postdoctoral Science Foundation (2022M721910), and the Shanghai Natural Science Foundation (22ZR1402400). The authors wish to record their gratitude for all the generous supports.

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Authors and Affiliations

  1. College of Mechanical Engineering, Donghua University, Shanghai, 201620, China

    Tangyong Zhang, Chongjun Wu, Cong Chen & Jianguo Zhang

  2. Aplos Machines Manufacturing (Shanghai) Co. Ltd., Shanghai, 201306, China

    Long Wang & Zhijian Lin

Authors
  1. Tangyong Zhang
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  2. Chongjun Wu
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  3. Cong Chen
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  4. Long Wang
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  5. Jianguo Zhang
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Contributions

Tangyong Zhang conducted the model setup and wrote the paper. Chongjun Wu designed the whole conception and theoretical analysis. Cong Chen and Long Wang helped in completing the experiments. Jianguo Zhang and Zhijian Lin contributed to polish the manuscript. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Chongjun Wu.

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Zhang, T., Wu, C., Chen, C. et al. 3D bevel surface topography analysis and roughness prediction by considering the cutter-workpiece dynamic interaction. Int J Adv Manuf Technol 129, 335–352 (2023). https://doi.org/10.1007/s00170-023-12265-5

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  • DOI: https://doi.org/10.1007/s00170-023-12265-5

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