Surface topomorphy and roughness prediction in micro-ball-end milling using a CAD-based simulation

摘要

Ball-end milling is a widely used finishing process in metal cutting. The small size and the complex of metal machining components are the main reasons for implementing milling in microscale. The surface profile and the dimensional accuracy are key factors on the quality of surface of a product. The selection of optimal cutting conditions can be accomplished by utilising simulation models which can involve the kinematics and the strategies of milling processes. Therefore, the analytical prediction of the produced surface quality (topomorphy and roughness) can be reached. The present study indicates a 3D simulation model of ball-end micro-milling process developed in commercial CAD software and its optical and computing results. Micro-milling experiments of Al7075-T6 were carried out in different conditions by the use of a high speed spindle. A computer application was developed to calculate the roughness out of the controlled points of a plane that intersects with the 3D workpiece. The calculated roughness was compared with the measured surface roughness and the surface topomorphy was captured through a stereo microscope.