Modeling and controlling of surface micro-topography feature in micro-ball-end milling

The machined surface micro-topography has a great influence on the surface quality and the surface function. A simulation algorithm of machined surface topography is present in this paper, in which the influence of the tool vibration is considered. From the overall surface texture formation, surface texture interval, surface texture height, and surface texture direction, the geometric characteristics of surface micro-topography in micro-milling was defined and investigated. The influence of process parameters, especially the initial phase angle of cutter and the tool vibration, on the geometric characteristics of surface micro-topography is investigated, and the method to control the process parameter is proposed. Especially, this paper presents a novel method, through the planning of noncutting tool path, to control the initial phase angle of cutter which has significant effect on surface topography. The experiments shows that the control deviation of the surface texture direction is less than 2°, and the machined surface topography consistent with the simulation result, which means that the modeling and controlling of surface topography is feasible and effective.