Surface generation during milling considering the tool micro geometry

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Cutting processes are often the final step within process chains and thus, largely responsible for the surface topography. In addition to design aspects, the surface topography determines the performance and service life of mechanically loaded components. While the surface deviations of 1st, 2nd and 3rd order are largely understood and can be explained by machine and clamping errors, kinematic influences and tool deflection, deficits still remain regarding the surface deviations of 4th order. Similar to the knowledge on surface formation the knowledge on modelling surface deviations of 4th order is limited. However, in order to optimize the design of components and further improve machining processes it is necessary to simulate the surface topography. Therefore, the aim of this project is to increase knowledge on the surface formation in flank milling under special emphasis of the tools microgeometry. Additionally, a novel modelling approach is developed in order to simulate surface deviation of 4th order.