Universal Surface Texture Modeling Method for Five-axis Surface Milling

To further improve the universality of five-axis milling surface texture simulation mod-cling method, and to provide reference for surface texture quality assessment considering tool attitude angle and classification, a kind of five-axis milling surface texture topography simulation method was proposed with general tool parameters and general curved tool contact coordinates. The tool cutting edge expression suitable for the surface texture process of five-axis milling of different tools and surfaces was established with the tool poses defined by the tool inclination angle φ and rotation angle Θ of the generality of annular milling cutter. Then, a surface texture simulation model was established with searching the grid points of the workpiece in the instantaneous swept quadrilateral through geometric relationship based on the idea of discretization and the expression of cutting edge points. Under different tool attitude angles, the surface texture simulation models of two traditional surfaces with different geometric characteristics plane, spherical surfaces and different types of freeform surfaces were established, according to the simulation results, the plane simulation morphology was divided into φ = 0° and φ ≠ 0°, and the efficiency of the simulation method was verified by comparing the plane simulation time. Finally, the plane cutting experiments were carried out. The results show that the actual cutting workpiece texture is basically consistent with the simulation texture morphology under the combination of Θ = -40°, φ = 20° and Θ = 15°, φ = 60°. At the same time, the actual cutting surface texture morphology characteristics arc consistent with the classification results of the simulated workpiece surface texture morphology, which further verifies the correctness of the surface texture morphology modeling and simulation methods. © 2023 China Mechanical Engineering Magazine Office. All rights reserved.