A model of milled surface generation for time domain simulation of high-speed cutting

Modelling the machined surface during time domain simulation is a complex and time consuming problem. However, calculation time can be reduced using specific models dedicated to milling operations. This research presents 2.5-dimensional geometrical modelling of the milled surface generation used in a time domain simulation of end milling operations. It is dedicated to the study of flexible workpiece-flexible tool system and high-speed cutting conditions. This modelling provides an accurate representation of the machined surface and is independent of the time discretization imposed by the dynamic of the cutting process. The material removal process is achieved by considering the effective paths of tool teeth relative to the workpiece, including vibrating motions of both tool and workpiece. At each time step the tooth motion is interpolated with a quadratic form model allowing low interpolation error even for long incremental tooth displacements. Simulation is compared with experimental results; the surface defects due to vibrating behaviour are shown, and a good correlation is obtained.