Towards understanding and controlling of the surface texture pattern in 5-axis ball-end milling using fast texture simulation

Surface texture is critical for the functionality of industrial parts. This work aims to effectively control the surface texture by applying the phase difference angle between adjacent cutting passes using 5-axis ball-end milling. Because the texture pattern is complicated and is formed by combining feed-interval and step-interval scallops, we propose a level-contour-based fast simulation method to effectively generate the surface texture by inputting the phase difference angle with tilt and lead angles of the cutter. After clarifying the influence of these three parameters on the texture pattern, the desired texture was controlled by modifying the tool path according to the simulated phase difference angle. As a result, the milled surface texture corresponded well with the simulation. The details of the cutting features were efficiently and comprehensively simulated. The mechanism underlying the sudden change in the texture ridge direction was clarified as the major-minor ridge transition when the phase difference angle increased to a certain level, wherein the surface roughness could be decreased because the rearrangement of the cutting region reduced the scallop height. The proposed fast simulation method was also applied to the optimization process with a case study to demonstrate the benefits it can bring to the surface texture design and control.