Influence and prediction of tool wear on workpiece surface roughness based on milling topography analysis

The surface quality of the workpiece has a great impact on the performance of the product. It has always been a key issue of the manufacturing discipline. The different wear levels of cutting tools determine the surface quality of the workpiece. Therefore, the work of this article is to establish a model for calculate the surface quality of the workpiece after milling. First, by defining the tool wear area S and the wear position angle ψ, the cutting edge line model of the tool is determined. Based on the tool motion trajectory and roughness calculation principle, a milling topography simulation roughness model considering tool wear is obtained. Secondly, the tool wear parameters were calibrated with the help of image detection methods, and the predicted values obtained by the model were compared with the experimental values. The law of the influence of the tool wear area S and the wear position angle ψ on the roughness parameters was obtained. Finally, the least squares support vector machine LS-SVM was used to verify the error of the roughness model of the milling topography simulation, and the result showed that the average error of the model was 8.68%.