Simulation of Surface-Microstructures Resulting from Milling Processes

In addition to the prediction of whether a milling process is free of chatter or not, the resulting surface quality is of importance. This paper presents geometric models of the machined workpiece in order to predict the surface microstructures of the peripherally milled flank structures as well as the surface resulting from the slab milling process with end-mills. After a brief explanation of the time domain simulation system used to calculate the tool vibration patterns, a surface model is presented which is able to predict the roughness depending on the spindle speed. Results show that the best surface quality is achieved by milling with spindle speeds which are slightly lower than at the stability maxima. Keywords: Milling simulation, chatter, surface modelin