Simulation And Analysis Of Surface Topography In Micro-milling

With the development of technology and society, micro parts have been widelyused in the aerospace, biomedical, communications, optics, fuel cell, etc. Micromachining has been widely applied in the fabrication of the micro parts and microstructure, which has many advantages, such as low costs, high flexibility, theprocessability of a wider range of materials etc. The surface topography has animportant effect on the surface quality and the products performance, such as surfaceroughness, fatigue resistance, surface friction, wearing, light reflection, heattransmission, etc. So the studies on the surface topography in micro-milling are ofsignificance.In this paper, the geometry characterization of the machined surface topographyin micro-milling is defined. The cutting motion model of micromilling is built, and theprogram is written. Using the simulation program, the influence of the processparameters is investigated. Especially, the influence of the path interval and federateper tooth on the surface topography in micro-milling is analyzed. It’s also pointed thatthe path interval and the fedrate per tooth have an important influence on the surfacetopography in micro-milling. Moveover, the influence of the inial phase angle onsurface topography is analyzed and studied. And a method to control the inial phaseangle between adjacent tool paths is proposed. The experiment results show that themethod is effective and feasible.The cutting motion model considering the tool vibration in micro-milling is built,and the influence of the tool vibration on the2D profiles is investigated. Then the influence of the tool vibration on the3D surface topography is analyzed, and theinfluence of the federate per tooth and the tool vibration amplitude on the surfacetopography is analyzed. It’s pointed out that the tool vibration increased the surfaceroughness remarkably. And if the amplitude of the tool vibration exceed a certainvalue, a phenomenon of single edge cutting appears, and the surface qualitydeteriorates quickly.In this paper, the area power spectrum density(APSD) is presented to analyze thesurface topography in micro-milling. And the relationship between the frequencydomain and the processing parameters is analyzed.