Comprehensive Simulation of Surface Texture for an End-Milling Process

The analysis and simulation of the manufacturing process require extensive and complicated computations. nowadays, computer resources and computational algorithms have reached the stage where they can model and simulate the problem efficiently. one of the important processes in manufacturing is machining. in this research, the end-milling process, which is one of the most complex and widespread processes in machining, is chosen. the most important parameters in end-milling are surface roughness and surface location errors. comprehensive simulation software is developed to model the end-milling process, in order to anticipate the finishing parameters, such as surface roughness and errors. the proposed algorithm takes into account cutting conditions, such as feed, doc, woe and tool run out etc. in addition, the dynamic simulation module of the software can accurately model the flexible end-mill tool, the milling cutting forces and regeneration of the waviness effects, in order to construct a realistic surface texture model. the software can accurately determine the most commonly used index of surface roughness parameters, such as ra, p.t.v. and surface errors.