Geometrical Simulation of Finished Surface Generated by Ball End-milling with Dynamic Motion Error of Feed Drive Systems

Dynamic motion errors are serious causes of blemishes on finished surface. However, there are few methods to simulate finished surface with dynamic motion error. The purpose of this study is to develop a simulation method that can predict the finished surface generated by ball end-milling considering also the influence of dynamic motion error. In this study, actual tool trajectories are calculated by dynamic model of feed drive systems and the trajectories were fed to a surface simulation software. Simulated surface is displayed with a renderer which can consider lighting and viewpoint properties. Cutting test of hemisphere shape is carried out for comparison purpose. From this test it is confirmed that the proposed method can predict the blemishes on the finished surface due to dynamic motion errors, and it is also clarified that different tool path choice could affect the influence of stepwise errors on the finished surface .