Realistic simulation of surface defects in 5-axis milling using the measured geometry of the tool

Sylvain Lavernhe (1) , Yann Quinsat (1) , Claire Lartigue (1) , Christopher Brown (2)

1 LURPA - Laboratoire Universitaire de Recherche en Production Automatisée
2 SML - Surface Metrology Laboratory

Managing macro and micro geometry of surfaces during manufacturing processes is a key factor for their fol- lowing uses. Indeed micro-geometry and surface topogra- phy are directly linked to the performances of functions (con- tact, friction, lubrication, etc.) by texture parameters to en- sure the desired local geometry. Common models for sim- ulation of surface topography are based on ideal geometry of the machining tool and cannot represent surface defects. The actual prediction and simulation of defects is one step forward in a competitive context. In this paper, the realis- tic model proposed aims to simulate and predict as finely as possible local defects of machined surfaces taking into ac- count the actual edge geometry of the cutting tool. The com- bined use of the machining kinematics and of the measured geometry of the cutting edges leads to the representation of the geometrical envelope of the surface using a Zbuffer tech- nique. Simulation assessment is carried out by the analysis of 3D surface topography parameters such as surface com- plexity and relative area, and by a comparison of simulation results to an experimental case of study.

Mots clés: Surface topography; Defects; Realistic modeling and simulation; Surface analysis; Surface machining

Domaines: Génie mécanique [physics.class-ph]; Génie mécanique [physics.class-ph]

Sylvain Lavernhe, Yann Quinsat, Claire Lartigue, Christopher Brown. Realistic simulation of surface defects in 5-axis milling using the measured geometry of the tool. International Journal of Advanced Manufacturing Technology, 2014, 74, pp. 393-401. ⟨10.1007/s00170-014-5689-7⟩. ⟨hal-01002334⟩