Study of the Topography of Face Milled Surfaces Using CAD-Based Simulation

The generation of high-quality machined surfaces is of great importance for a series of applications. Face milling is one of the most common processes for machining such surfaces; the process is influenced by a series of factors that if not taken into consideration would result in poorly machined surfaces. The cutting parameters, the cutting tool design and the setup of the cutter and the workpiece play a pivotal role in the success of the machining process. In order to understand the effect of each parameter on the resulting surface quality of face milled surfaces, the current research presents a simulation model that is able to incorporate all the factors mentioned above in a CAD-based simulation platform. The results of the model include the resulting surface topography as well as surface roughness metrics. The results of the simulation approach were validated with experimental results.