Study on an end milling generation surface model and simulation taking into account of the main axle’s tolerance

In accordance with the relative movement between an end-milling cutter and the workpiece surface, a theoretical generation model for a milled surface was established with the movement error of principal axle being considered. Then the milled surfaces under various cutting condition were simulated, the results of which showed that end milled surfaces were of “vaulted profile”, the heights of surface irregularity at various points being different with the maximum value at the middle and a smaller value at both sides. The difference was determined by the diameter of the milling cutter, the feeding speed, the ratio between the diameter of the milling cutter and the teeth point curve radius, and the width of the workpiece. The study results can be applied to the quality prediction of milled surfaces for precision and/or super precision milling operations.