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Acta Armamentarii ›› 2022, Vol. 43 ›› Issue (8): 1977-1989.

• Paper •

### Modeling and Simulation of Surface Topography under Ball-end Milling Based on Dynamic Response of Milling System

DONG Yongheng1， LI Shujuan1， ZHANG Qian2， LI Pengyang1， LI Qi1， JIA Zhen1， LI Yan1

1. (1.School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, Shaanxi, China; 2.School of Mechanical and Electrical Engineering, Guilin University of Electronic Science and Technology, Guilin 541004, Guangxi, China)
• Online:2022-07-20

Abstract: Milling surface topography modeling based on the dynamic response of the weak-stiffness ball-end milling system has an important theoretical value for improving surface quality. To do this, first of all, the kinematic trajectory of the ball-end milling cutter teeth is established by homogeneous coordinate transformation, and a solution for the milling force is put forward according to the mechanical modeling method. A dynamic model for the flexible cutter-flexible workpiece milling system is established based on the regenerative vibration theory. A method for solving dynamic displacement of processes based on the full discrete method with the effect of variable time delay considered is proposed. And a linear interpolation method is adopted to modify the cutter tooth trajectory. Then, a simulation method for the surface topography under ball-end milling is proposed by combining Z-MAP method and numerical method. After completing geometric simulation of the surface topography generated by the machining path, a physical simulation considering the dynamic displacement of the process system induced by vibration is carried out. Lastly, a validation experiment is conducted by milling material 7050-T6 using a carbide ball-end milling cutter. The experiment and simulation results are consistent, indicating that the modeling method is effective and can provide theoretical basis for selecting and optimizing actual machining parameters.

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