Modeling of Surface Topography after Milling with a Lens-Shaped End-Mill, Considering Runout

The paper presents a method of forecasting the product surface topography after five-axis machining with a lens-shaped end-mill. Surface roughness is one of the key parameters considered when assessing the effectiveness of the machining process, especially in the aviation, automotive, tooling and medical equipment industries. The developed method, the first published, presented in the paper is based on the analytical equations of the trajectory of the cutting edge motion, on the basis of which the cutter action surface is generated. The developed model takes into account: cutting depth, cutting width, feed, lead angle and radial runout. Experimental studies were conducted using three different materials: 40HM steel, Al7035 aluminum alloy and Ti Grade 5 titanium alloy. Various values of the cutting width parameters and different feeds were used in the tests. Based on the results of the experimental tests, an empirical model (response surface model) was determined and was then used to verify the simulation model. The simulation results and the results of experimental tests were compared and conclusions were drawn regarding the developed models. The developed models supported by numerical simulation can be used to approximately estimate the influence of the width of cut [Formula: see text] and feed [Formula: see text] on selected height characteristics [Formula: see text] and [Formula: see text] of the geometric structure of the surface (GSS) after machining with a lens-shaped end-mill in terms of the process parameters adopted in the tests. It was found that the influence of the [Formula: see text] on the [Formula: see text] and [Formula: see text] is greater for small values of [Formula: see text]. The effect of [Formula: see text] is greater with lower [Formula: see text] values. The cutting width [Formula: see text] has the greatest influence on [Formula: see text] and [Formula: see text] , and [Formula: see text] and the interaction of these parameters has the least influence.