Milling Simulation Based on A Boundary Geometry Method

doi:10.3901/JME.2025.13.418

Abstract

Abstract: Accurate modeling of milling forces and tool vibrations is crucial for the simulation of milling processes. Taking into account the nonlinear dynamic regenerative effects of the milling system, a boundary geometric method for simulating the milling process is proposed by superimposing the changes in tool position caused by tool vibrations and tool runout onto the milling trajectory. The physical features of the tool teeth and workpiece can be characterized with the micro segments, in which the identification of the tool-workpiece cutting contact area and calculation of the instantaneous undeformed chip thickness can be obtained through the geometric relationships between these micro segments. And the material removal from the workpiece is accordingly achieved by scanning the cutting area with the tool teeth micro segments. On this basis, the micro-element integral method is used to calculate the milling forces, and then the dynamic equation of the milling system is established, with the tool vibration displacements solved using the fourth-order Runge-Kutta method. To verify the reliability of the simulation model, experiments are conducted to measure the milling forces and tool vibration displacements. The experimental results show that the milling force and tool vibration displacements can be accurately predicted by the established simulation model, with relative errors of less than 10%, thereby laying a foundation for subsequent digital research on milling processes.

Key words: milling simulation, boundary geometric method, milling force, tool vibration

CLC Number:

TG156

ZHANG Jun, LI Yi, TANG Weimin, GE Shuyi, GUO Demin, LUO Haiwei. Milling Simulation Based on A Boundary Geometry Method[J]. Journal of Mechanical Engineering, 2025, 61(13): 418-428.

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