Simulation Efficiency Optimization Method of Flank Milling for Nondevelopable Ruled Surface Based on Cutting Contact Conditions

Surface topography simulation is crucial in studying the surface texture of workpieces, controlling processing quality, and optimizing process parameters. Nondevelopable ruled surfaces are often used for high-precision surface components due to their unique geometric features, making the simulation method of non-developable ruled surfaces an area of widespread interest among scholars both domestically and abroad. However, due to the geometric characteristics of nondevelopable ruled surfaces and the characteristics of flank milling processing, current simulation efficiency optimization methods are not suitable for simulating the topography of nondevelopable ruled surfaces in flank milling processing. To solve the problem of low simulation efficiency of traditional morphology simulation algorithms based on Z-map method, this paper proposes an efficiency optimization method for simulating the topography of nondevelopable ruled surfaces in flank milling processing based on the cutting contact condition. In the proposed method, the tool pose traversal process constrained by flank milling contact condition was introduced to the traditional simulation method aiming at reducing the number of cycles for updating residual height of the local surface. Finally, the effectiveness of the optimization method proposed in this paper is verified by simulation experiments and processing experiments.