Modeling and simulation of machined surface error in micro-ball-end milling

By taking into account the scale effects, a micro-ball-end cutting force model is established. Firstly, the cutter is simplified as a ladder shaped cantilever beam. Secondly, virtual displacement principle is combined with machine-workpiece system deformation to obtain the cutter deformation with micro-ball-end cutting force. Thirdly, the deformation is coupled into the cutting edges trajectories. Finally, a new milled surface topography model is developed, which synthetically considers spindle runout, minimum chip thickness, cutter deflection and machine-workpiece system deformation. An algorithm for physical simulation of three-dimensional micro-ball-end milled surface topography is proposed. A simulation example is given and the factors affecting the milled surface accuracy are analyzed. Experimental results demonstrate the validity and the applicability of the algorithm.