Surface Morphology Modeling And Experimental Study Of Micro End-milling

Micro end-milling is a precision manufacturing technology with good engineering application value,but the surface quality of micro end-milling is difficult to measure or evaluate directly,and the research on the mechanism of surface generation has not yet reached a mature theoretical model.Therefore,in this paper,the micro ball end-milling process is used as an experimental method,and the theoretical model of the surface morphology after the micro ball end-milling process is studied in depth,and the micro-milling effect that influence the appearance of surface result is studied as a key technical issue.The research has completed the following work:Firstly,the theoretical analysis of the coordinate transformation in the process of micro ball end-milling is carried out,and the change rule of the cutting point of any tooth of the micro ball end-milling cutter in the workpiece coordinate system is obtained,thus providing a theory basis for the subsequent simulation modeling of the overall surface shape of the ZMap algorithm.After that,the overall surface morphology simulation model of micro ball end-milling is generated by using the Z-Map algorithm.The algorithm contains the work of dividing the workpiece surface into grids,and using discrete grid nodes to describe the height information of each position on the workpiece surface.Through continuous iterative calculation,the simulation result of the overall surface morphology of the workpiece after micro ball endmilling process is finally obtained.The expression of the surface residual contour after micro ball end-milling process is obtained through mathematical calculation considering cutting edge effect and minimum cutting thickness.Through theoretical analysis,it is found that when two micro-scale effects are considered at the same time,the peak of the surface residual contour generated by micro ball end-milling process is basically the same in the cross-sections of different heights along the depth of the groove,and using smaller clearance angle cutter as well as less feed per tooth can effectively improve the surface quality of micro ball end-milling.Finally,through the micro ball end-milling experiment,the experimental result of the surface morphology is obtained,then the simulation result and experimental result of the micro ball end-milling are compared and analyzed by using two methods: average relative error and power spectral density value.The deviation between the simulation result and the experimental result is finally obtained which verifies the correctness of the theoretical simulation model as well.