Simulation of machined surface topography in end-milling processes using a shear-plane-based cutting force model

The purpose of this paper is to extend the theoretical understanding of the dynamic milling process and to derive a computational model to predict machined surface topography using, as the foundation, a newly developed shear-plane-based rather than the customary chip-thickness-based cutting force model. The machined surface is synthesized by concatenating two-parameter bicubic surface patches generated by discretized cutting edge segments as they follow their respective trajectories. To maintain positional and tangential continuity, both the coordinates of nodal points on the cutting edges and the associated instantaneous velocities are used to construct the surface patches. A computer simulation program that incorporates the shear-plane-based cutting force model and geometric, kinematic and surface topography prediction models is developed. Computer simulations and cutting tests confirm the validity of the computational models.