AN ENHANCED END MILLING SURFACE TEXTURE MODEL INCLUDING THE EFFECTS OF RADIAL RAKE AND PRIMARY RELIEF ANGLES

An enhanced surface texture model for predicting the two- and three-di mensional structure of the surface generated by the end cutting edges on the bottom of an end mill is presented. This model includes the eff ects of the radial rake and the primary end tooth relief angles which have been neglected in the models available to date. Non-ideal effects such as cutter runout and back-cutting are explicitly modeled. An alg orithm to simulate the two- and three-dimensional milled surface is pr esented. It is shown that the main effect of the radial rake and the p rimary end tooth relief angles is to increase the surface roughness pa rameter values. The effectiveness of the enhanced model in accurately capturing the major features of the machined surface texture and in cl osely predicting the roughness parameter values is demonstrated throug h experiments and model simulations. It is shown that the enhanced mod el predicts both the shape of the surface profile and the surface roug hness parameters more accurately than the existing models in the liter ature.