Surface Topography Modeling And Characterization And Evaluation Of Five-axis Flank Milling

Surface topography is the key factor to evaluate the quality of 5-axis flanking milling.Analysis of the influence on surface topography and the way to predict are important research topics in the field of mechanical manufacturing at home and abroad.Due to the processing method particularity of flank milling,the influence of the processing parameters on the surface topography is different from that of the other milling.So how to characterize the stochastic topography and establish a mathematical model to predict it and clarify the mechanism of the factors on surface topography,and characterize and evaluate the surface are all urgent problems to be solved.This paper establishs a stochastic topography prediction model based on the Pearson distribution.The influence of the factors to the surface topography such as processing parameters,up-milling and down-milling,tool runout,are analyzed.The influence of the tool surface roughness on the topography and the feed mark appeared during machining are analyzed.Measurement,characterization and evaluation are done on Five-axis machining surface.The model is verified and the results of the factors are explored by experiments.The main research contents are as follows:(1)The principle of surface topography generation was analyzed and the prediction model of stochastic topography in flank milling is established aiming at the characterization and prediction of surface topography.This model combined the advantages of empirical and analytical models,and used Pearson random numbers to characterize random factor,this method broke through the limitations of experimental conditions and improved the prediction accuracy of stochastic topography.The model is validated by flank milling experiment,and it showed that the model had better prediction accuracy than the previous model within certain processing parameters.(2)The influence of process factors on the surface topography in five-axis flank milling was studied.Researchs were done to analyze the different effects of up-mill and down-mill on the surface roughness.Through the statistical analysis of experimental data,the difference between actual milling roughness and theoretical roughness was analyzed.The mechanism of the influence of the tool runout on the surface topography was analyzed in detail,and the model of the roughness parameter under different conditions considering the tool runout was put forward.The accuracy of this model is verified experimentally.(3)Five-axis flank milling surface was measured.Power spectral density was used to analyze the surface and fractal method was used for characterization.The relationship between dimension and surface roughness was analyzed.The influence of the chatter on the five-axis machining workpiece surface was explored,the relationship between the different processing parameters and chatter was analyzed.