Simulation of surface structuring considering the acceleration behaviour by means of spindle control

Freiburg, D.1, a; Finkeldey, F.1, b; Hensel, M.1, c; Wiederkehr, P.2, d; Biermann, D.1, e

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund
Lehrstuhl 14 Software Engineering – Virtual Machining, Technische Universität Dortmund, Otto-Hahn-Straße 12, 44227 Dortmund

a); b); c); d); e)


Due to the increasing demands on surface quality of machined surfaces, deviations of the feed velocity, which can occur in complex 5-axis milling processes and are caused by the insufficient acceleration and deceleration behaviour of the machining centre, have to be avoided. This is crucial in the case of surface structuring by means of high-feed milling. The high-feed rate can be used to generate quasi-deterministic surface structures on forming tools. Applying surface structures for forming processes, the friction can be tailored to improve the form filling of small cavities. However, in order to generate homogeneous surface structures, it is important to ensure a constant feed per tooth during the milling process. In this work, a novel approach for the predicting surface structures using a geometric physically-based simulation system is shown. Furthermore, an empirical model was developed which represents the acceleration and deceleration behaviour of the used machining centre for predicting the deviations of the feed rate. Therefore, it is possible to take the alternating feed rate into account when simulating the milling process. In addition, a control approach, for adapting the spindle speed online, is used to keep the tooth feed constant.


milling simulation, surface structuring, control


International Journal of Mechatronics and Manufacturing Systems, 11 (2018) 1, S. 67-86, doi: 10.1504/IJMMS.2018.10012330