Prediction of measured surface topography with forced vibration effects

Predicting the surface topography of machined surfaces is an effective way to assess the dimensional accuracy and surface roughness of milling, which is influenced by the forced vibration of the cutter. To solve this problem, this paper proposes a method to predict the measured surface topography in flank milling under multi-order mode-dominated forced vibration. Comprehensively considering tool geometry, cycloidal tooth trajectory interaction, and cutter runout effects, an accurate milling surface topography model is presented first. Then, the mechanism of cutting force and forced vibration effects on the machined surface topography is analysed. Finally, cutter runout parameters are identified, the features of cutter forced vibration are isolated, and flank milling experiments validate the model accuracy and the validity of the proposed theory. The simulation and experimental results demonstrate that the proposed method effectively predicts the measured surface topography of flank milling, considering forced vibration effects.