Modelling of surface roughness and studying of optimal machining position in side milling

In this work, a theoretical analysis of surface generation numerical model is presented to predict the surface roughness achieved by side milling operations with cylindrical tools. This work is focused on the trajectory of tools with two teeth by influencing of tool errors such as radial runouts, as well as straightness with dynamic effects. A computational system was developed to simulate roughness topography in contour milling with cylindrical tool. Finally, the PSO (particle swarm optimization) algorithm is employed to find the optimal machining position for the best surface roughness. Experimental data is satisfied with the the novel pretiction model for the tooth’s trajectory, and the the final prediction accuracy is high enough, i.e. that the prediction surface roughness. Low prediction surface roughness error (1.37 ~ 15.04%) and position error (0.95 ~ 1.25 mm) indicate effectiveness of the model built in this work. The novel model may be used to determine the variation in surface roughness.