General characterization of peripheral milled surface geometry by feature element

Traditional peripheral milled surface models, whether resulting from analytical or numerical method, are targeted at solving numerical points of the surface. However, the independent coordinate point is lack of geometric or physical meaning due to its incompetence of description for milled surface geometry and connection with milling conditions, unless all the discrete points are engaged. Such surface characterization or the corresponding modelling method based on point is flawed inherently that lead to its less suitable for study of surface parameters or effect factors. Therefore, a new idea and methodology are introduced. Firstly, geometric feature element of the peripheral milling surface is defined, by analyzing periodic feature of the surface residue profile in stable milling process with the presence of cutter runout. Then, taking three and four teeth cutter milling situations as example, systematic theories and methods are developed for calculating and analyzing of the feature element. Thirdly, via simulation tests of milled surface geometry, superior modelling performance in accuracy and efficiency of the feature-based method are verified in contrast with the integrated analytic and numerical method, the simulated surface based on which is perceived as the theoretical true result. All the effort devoted to this new idea proves that the defined geometric feature element is qualified for characterization of milled surface geometry, which not only improves the surface model but also will be convenient to the further study in surface quality and functionality.