Modeling and analysis of a novel approach in machining and structuring of flat surfaces using face milling process

•For the first time; an innovative method for generation of regular patterns on the workpiece surface is presented.•Mathematical models of pattern machining during face milling process are firstly introduced.•A correlation program programmed with MATLAB and CAD programming software is developed.•Face milling tests are carried out to verify the theory and mathematical modeling.•The influence of different machining process parameters on pattern geometry is analyzed.

In this paper, a new and innovative method for regular structuring and special patterning of workpiece surface applying face milling process is presented. The patterns have been generated on surface by particular positioning of workpiece and tool, milling passes in different directions, and as well as special angular position of spindle in typical vertical milling machine. The model for the geometry of the cutting tool was first developed and subsequently, a new simulation model for surface pattern by face milling process was established. Mathematical models are presented to describe the cutting tool geometry and position (including orientation and location) in space. To verify this method, calculation and simulation programs (MATLAB and CAD programming software) are developed. This study provides a fundamental understanding for the pattern milling process, based on this, the influence of different milling process parameters on pattern geometry (including insert angles and radius) is discussed. The simulation results could be used to optimize the pattern milling and conventional milling processes, and also to improve the workpiece surface quality or predict the surface pattern by given face milling parameters.