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

Managing macro- and micro-geometry of surfaces during manufacturing processes is a key factor for their following uses. Indeed, micro-geometry and surface topography are directly linked to the performances of functions (contact, friction, lubrication, etc.) by texture parameters to ensure the desired local geometry. Common models for simulation of surface topography are based on ideal geometry of the machining tool and cannot represent surface defects. The actual prediction and simulation of defects are one step forward in a competitive context. In this paper, the realistic model proposed aims to simulate and predict as finely as possible local defects of machined surfaces taking into account the actual edge geometry of the cutting tool. The combined 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 technique. Simulation assessment is carried out by the analysis of 3D surface topography parameters such as surface complexity and relative area and by a comparison of simulation results to an experimental case of study.