The effects of machining process variables and tooling characterisation on the surface generation

The paper presents a novel approach for modelling and simulation of the surface generation in the machining process. The approach, by integrating a dynamic cutting force model, regenerative vibration model, machining system response model and tool profile model, models the complex surface generation process. Matlab Simulink is used to interactively perform the simulation in a user-friendly, effective and efficient manner. The effects of machining variables and tooling characteristics on the surface generation are investigated through simulations. CNC turning trials have been carried out to evaluate and validate the approach and simulations presented. The proposed approach contributes to comprehensive and better understanding of the machining system, and is promising for industrial applications with particular reference to the optimisation of the machining process based on the product/component surface functionality requirements.