Construction and validation of a surface topography prediction model for milling with double-arc milling cutter

Abstract

Addressing the limited research on surface topography modeling for non-conventional tools with diverse geometries, a method for constructing a surface topography prediction model for double-arc milling cutter(DAMC) is proposed. By innovatively segmenting the cutting edge, this method incorporates the double-arc cutting edge into the Z-map height field calculation, while simultaneously accounting for the inclination angle and cutting parameters. Integrating the Z-MAP method with the actual milling process of the DAMC enables a geometric description of the tool-workpiece contact. By discretizing the workpiece surface and dynamically updating the grid point heights to simulate the machining process, the proposed method enables the accurate calculation of the three-dimensional topography. Experiments were conducted with two types of DAMC. Results demonstrate high consistency between simulations and experiments in terms of three-dimensional topography distribution, two-dimensional profile curves, and surface roughness Sa, with an average prediction error of 7.32% for Sa. Analysis shows that the feed per tooth fz is significantly positively correlated with Sa, and when fz increases from 0.1 mm/z to 0.133 mm/z, Sa increases significantly. There is an optimal range for the inclination angle alpha. This study provides a theoretical basis for the selection and optimization of DAMC tool parameters and cutting parameters, important guidance for improving surface quality, and important theoretical basis for studying the surface topography of non-conventional tools.