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 Comprehensive Simulation of Surface Texture for End Milling Process­

 

Abstract: Analysis and simulation of manufacturing process require extensive and complicated computations. But nowadays, computer resources and computational algorithms reach to the state that can model and simulate the problems efficiently. One of the important processes in manufacturing is machining. In this research, end-milling process, which is one of the complex and wide-spread processes in machining, is chosen. Most important parameters in end-milling are surface roughness and surface location errors. A comprehensive simulation software is developed to model end-milling process in order to anticipate finishing parameters such as surface roughness and errors. The proposed algorithm take into account cutting conditions such as feed, DOC, WOC, tool run out, etc. In addition, dynamic simulation module of the software can accurately model flexible end-mill tool, the milling cutting forces, and regeneration of waviness effects in order to construct realistic surface texture model. The software can accurately determine parameter Ra, P.T.V. and surface errors.

Keywords: Machining Simulation, Regeneration, End-milling, Surface Texture, Surface Roughness ­

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