Model for the prediction of 3D surface topography in 5-axis milling

The paper deals with the prediction of the 3D surface topography obtained in 5-axis milling in function of the machining conditions. For this purpose, a simulation model for the prediction of machined surface patterns is developed based on the well-known N-buffer method. As in sculptured surface machining the feed rates locally vary, the proposed model can be coupled to a feed rate prediction model. Thanks to the simulation model of 3D surface topography, the influence of the machining strategy on resulting 3D surface patterns is analyzed through an experimental design. Results enhance the major influence of the tool inclination on 3D topography. Surface parameters used in the study are strongly affected by the variation of the yaw angle. The effect of the feed rate is also significant on amplitude parameters. Finally, the analysis brings out the interest of using surface parameters to characterize 3D surface topography obtained in 5-axis milling.