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Surface topography is a critical factor influencing the precision, performance, and longevity of machined parts. Modeling and simulating surface topography for various milling processes, particularly 5-axis high-speed milling, remains an essential area of study to enhance manufacturing accuracy and efficiency. This work explores advancements in Z-MAP algorithms, widely used to model the topography of surfaces for ball end milling process (BEMP), and evaluates recent techniques to improve computational efficiency while maintaining accuracy. A Z-MAP algorithm is proposed that uses the Cutter Workpiece Engagement Region (CWER) calculation to minimize computation time. This method provides a robust solution to the conventional approach's limitations, enabling accurate surface topography simulation under diverse milling parameters with optimized efficiency. This paper presents the validation of a Z-MAP algorithm integrating CWER, using experimental data from 3-axis and tilt orientation of the tool.

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Efficient Surface Topography Prediction Using Enhanced Z-MAP Algorithms for Ball End Milling Process

  • 会议论文

  • 发表日期：

    2025年

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  • M. Maaloul,
  • R. Belguith,
  • A. Regaieg,
  • A. Amrouche,
  • L. Sai

摘要

Surface topography is a critical factor influencing the precision, performance, and longevity of machined parts. Modeling and simulating surface topography for various milling processes, particularly 5-axis high-speed milling, remains an essential area of study to enhance manufacturing accuracy and efficiency. This work explores advancements in Z-MAP algorithms, widely used to model the topography of surfaces for ball end milling process (BEMP), and evaluates recent techniques to improve computational efficiency while maintaining accuracy. A Z-MAP algorithm is proposed that uses the Cutter Workpiece Engagement Region (CWER) calculation to minimize computation time. This method provides a robust solution to the conventional approach's limitations, enabling accurate surface topography simulation under diverse milling parameters with optimized efficiency. This paper presents the validation of a Z-MAP algorithm integrating CWER, using experimental data from 3-axis and tilt orientation of the tool.