Desenvolvimento e teste de algoritmo para simulação da topografia da superfície resultante de fresamento topo esférico e topo reto

Abstract

Milling is one of the most common machining processes utilized by the industry, it allows for the machining of high surface qualities, but to attain such high surface qualities it is necessary to minimize the vibrations of the machining process, as one most important factors that affect the surface quality is the vibrations that occur during the machining process. Despite that fact modern CAD/CAM softwares available in the market still doesn’t account for the vibrations of the machining process, which opens up possibilities for research in the area of using computational methods to simulate said vibrations and the accuracy of such simulations. Therefore the objective of this research is to compare computer made simulations of the topography of end milled and ball milled surfaces and experimental milled parts, to ascertain the precision of the former. Those simulations will be made using a previously developed algorithm. The algorithm uses MATLAB and data from the material and machine to simulate the tool path and with it approximate the thickness of the resulting chip, which allows for the calculation of the cutting forces and vibrations, with that it is possible to make three coordinate matrices, one for each direction: X, Y and Z. Those matrices are then data processed and transformed into a 3d mesh that represents the expected topography of the resulting milled part. Those simulations will then be compared to the topography of the experimental parts machined with end mills and ball-end mills, to test their accuracy.