Modeling of Surface Structures Resulting from Vibrating Milling Tools

Weinert, K.^{1, a}; Surmann, T.^{1, b}; Müller, H.^{2, c}

1)

Institut für Spanende Fertigung, Universität Dortmund, Baroper Str. 301, 44227 Dortmund

2)

Lehrstuhl Informatik VII, Universität Dortmund, Otto-Hahn-Str. 16, 44227 Dortmund

a) weinert@isf.de; b) surmann@isf.de; c) mueller@ls7.cs.uni-dortmund.de

Kurzfassung

Besides the prediction of whether a milling process is free of chatter or not, the resulting surface quality is of importance. This paper presents a geometric model of the machined workpiece in order to predict the surface structure, which is produced by vibrating milling tools. After a brief explanation of the time domain simulation system used to calculate the tool vibration patterns, a surface model is presented which uses intermediary results of the simulation. This surface model consists of a dense set of points representing the surface. A line segment is assigned to each of these points, which is directed into the negative normal direction of the surface. The pairs of points and line segments (pins) represent a crust of the surface. Each simulated tool move adds and removes pins. The surface model is able to represent very fine structures such as chatter marks. In order to predict the expectable surface errors resulting from the real process, the set of points can be analyzed and visualized photorealistically by a point rendering method.

Schlüsselwörter

Computer Aided Engineering, Milling Simulation, Chatter

Veröffentlichung

Production Engineering. Research and Development, 13 (2006) 2, S. 133-138