Surface relief formation in peripheral end milling

Abstract

Theoretical studies of peripheral milling and the results of simulating the construction of a 3D relief of the machined surface have been presented. A digital model of the surface relief formation during peripheral milling with an end mill has been developed. The related simulating algorithm has been created. The milling process model is compiled taking into account the dynamic phenomena occurring in a closed technological machining system (TMS) and machining along the trace, represented by a function of a delay argument. The dynamic system is represented by a single-mass model with two degrees of freedom. The created application program for simulating peripheral milling with an end mill makes it possible to predict the power parameters of the cutting process and the geometric and machining parameters, depending on the geometric parameters of the cutter and workpiece, cutting mode, and dynamic characteristics of TMS. A 3D relief of the machined surface has been constructed. Its geometric component consists of the shape of micro-roughness, formed from the geometric engagement of the cutting edge of the helical mill with the workpiece and the elastic movement of the TMS. Simultaneously, it corresponds to the interaction of the next cutter tooth along the helix. The created application program makes it possible to predict the microrelief of the machined surface depending on the main TMS parameters.