Prediction of Surface Pattern by Spherical Approximation of Cutter Marks Array Generated with Ball-end Milling

Abstract

In this research, the surface pattern generated with ball-end milling was analyzed with the spherical approximation of cutter marks. The passage trajectory on machined surface with the cutting edge of ball-end mill was approximated on the spherical surface. The equation of plane was calculated from the overlapping of spherical surfaces and the machined surface, and then the ridge line of surface pattern can be given by the equation of line calculated from the intersection of these planes. From the simulation results of focus attention on the cutter marks in feed direction, it is shown that the width of cutter marks in feed direction increases in proportion to the sine ingredient of tool tilting angle and the eccentricity of tool axis.