Characterization of 3D surface topography in 5-axis milling

TL;DR

This paper presents a simulation model for predicting 3D surface topography in 5-axis milling, integrating material removal and inverse kinematics to improve surface quality prediction based on machining conditions.

Contribution

It introduces a novel simulation approach combining the N-buffer method with inverse kinematics for accurate surface topography prediction in 5-axis machining.

Findings

Model accurately predicts surface topography under various conditions

New areal surface roughness parameters effectively characterize surface quality

Simulation results align with experimental assessments

Abstract

Within the context of 5-axis free-form machining, CAM software offers various ways of tool-path generation, depending on the geometry of the surface to be machined. Therefore, as the manufactured surface quality results from the choice of the machining strategy and machining parameters, the prediction of surface roughness in function of the machining conditions is an important issue in 5-axis machining. The objective of this paper is to propose a simulation model of material removal in 5-axis based on the N-buffer method and integrating the Inverse Kinematics Transformation. The tooth track is linked with the velocity giving the surface topography resulting from actual machining conditions. The model is assessed thanks to a series of sweeping over planes according to various tool axis orientations and cutting conditions. 3D surface topography analyses are performed through the new areal surface roughness parameters proposed by recent standards.