Design of an Algorithm to Simulate Surface Roughness in a Turning for an Integrated Virtual Machine Tool

The fundamental issues to evaluate machine tool's performance through simulation pertain to the physical models of the machine tool itself and of process while the practical problems are related to the development of the modular software structure. It allows the composition of arbitrary machine/process models along with the development of programs to evaluate each state of machining process. Surface roughness is one of the fundamental factors to evaluate machining process and performance of machine tool, but it is not easy to evaluate surface roughness due to its tribological complexity. This paper presents an algorithm to calculate surface roughness considering cutting geometry, cutting parameters, and contact dynamics of cutting between tool and workpiece as well as tool wear in turning process. The designed virtual machining system can be used to evaluate the surface integrity of a turned surface during the design and process planning phase for the design for manufacturability analysis of the concurrent engineering.