Simulation and experimental study on 3D surface topography in micro-ball-end milling

The surface topography of milled workpieces often defines their performances, and it directly affects the precision and service life of parts. In view of the influence of tool inclination angle on the 3D surface topography in micro-ball-end milling, this paper carries out micro-milling surface predictions and tests based on the theoretical model of cutting edge trajectory model, providing technical basis for the high-precision machining of micro-surface. A theoretical model for the description of the cutting edge trajectory is established prior which takes inclination of cutter, flutter, run-out, cutting force, and plastic deformation of the material into account. Then, the surface topography and roughness are predicted based on the model. In addition, a series of newly designed surface topography experiments are carried out to verify the prediction. Through the comparison of the simulated micro-surface with the experimental results, the theoretical model showed considerable reliability, which means the 3D surface topography could be well controlled with the parameter recommended by the constructed model under certain conditions. The above research has a great significance in improving machining quality.