Machined surface prediction and reliability analysis in peripheral milling operations

The performance improvement of machine tools can be constrained by limited understanding of machined surfaces and machining quality reliability. In this paper, attentions are paid to the prediction of machined surface and the reliability analysis of machining quality for a three axis vertical machining center using peripheral milling operations. The prediction model of the machined surface in peripheral milling operations is developed considering the kinematic trajectories of all flutes, the run-out of tool, as well as the dynamic displacements of the cutter and workpiece. The dynamic displacements of the cutter and workpiece can be analytically calculated by the dynamics models of the tool and workpiece clamping systems of the machine tool. The location errors and roughness parameters are used to evaluate the quality of machined surfaces, and the reliability analysis method of machining quality is proposed considering the multiple failure modes. The proposed prediction method is verified during the peripheral milling of workpiece under different cutting conditions. The influences of some parameters on the machined surface are analyzed, and the machining quality reliability of the machine tool is also calculated and analyzed. This study can provide a theoretical basis for the design and optimization of machine tools and cutting tools, as well as the optimum design of processing conditions.