Prediction model of peripheral milling surface geometry considering cutting force and vibration

Milling surface quality is an important factor to assess the performance of a product, which is usually affected by cutting parameters. This paper presents a novel model of peripheral milling surface topography considering tool vibration. The model used the idea of discretization by introducing the milling dynamics and ignored the effect of tool wear, tilting, and thermal deformation. The simulation results were verified and showed good consistence with experimental results. Afterwards, parametric analysis was conducted to investigate the impact of process parameters and showed that feed per tooth impacts most on the surface roughness while axial depth of cut has the least impact. The presented method enables researchers to predict the peripheral milling surface before processing. Moreover, the method helps to build the formula of surface roughness to conduct the parameter optimization.