A surface generation model for micro cutting processes with geometrically defined cutting edges

摘要

Conventional machining techniques like milling and turning are well established techniques in manufacturing. In the last years considerable progress in miniaturisation of components has been made. Micro-machining operations have made the production of small components flexible, but scaling down these processes is extremely challenging. In the production of dies and molds special attention is paid to the forming zone where surfaces interact under heavy stress. Optimization of the tribological behaviour has been investigated over the last few years due to high rejection rates. The simulation of micro-structures and topographical characterisation are essential factors for the study of the functional performance of surfaces. Our contribution is a numerical surface generation model, which is able to simulate the micro-topography for machining operations with geometrically defined cutting edges. In the presented model the tool-workpiece kinematics are described by static and dynamic motions, including tool run-out and tool deflection caused by cutting forces. In the material removal algorithm, the minimum chip thickness and tool wear are considered. Experiments for ball-end milling are carried out for different process parameters to verify the simulation results.