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<p>As key components in fields such as aerospace and petrochemical engineering, circular pipelines require high-precision cutting, which serves as the fundamental prerequisite for reliable maintenance and connection. To address the challenge of predicting the surface accuracy in the side milling of circular pipes, this paper proposes a geometric simulation algorithm for end mill side milling of circular pipes (SESC) based on the Z-map discrete grid method. The core of this algorithm comprises two parts: first, converting the continuous machined surface into a grid lattice through discretization and establishing a tool-workpiece contact judgment model based on the Z-map theory; second, constructing a tool trajectory transformation chain involving 6 sets of coordinate systems to achieve an accurate mathematical description of the complex motion trajectories of ordinary and serrated end mills within the annular enclosed space. Simulations are conducted based on SESC to systematically analyze the influence laws of the tooth profile parameters of serrated end mills, feed per tooth, tool deformation, and tilt angle on the surface topography, while revealing the unique side milling characteristics of serrated end mills. Side milling experiments with serrated end mills are carried out under different feed per tooth values. The results show that both the comparison between experimental and theoretical simulation results in terms of 3D geometric topography and the comparison of roughness results (with a maximum error of 14.26%) confirm the correctness of the SESC. This method provides an effective theoretical tool for the surface quality control of circular pipe side milling.</p>

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Study on side milling algorithm of circular pipeline with end mills based on Z-map method and its simulation

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Xiaoquan Hao,
  • Peng Gao,
  • Kefeng Jiao,
  • Feihong Yun,
  • Gang Wang,
  • Liquan Wang,
  • Yu Chen,
  • Yuming Du

摘要

As key components in fields such as aerospace and petrochemical engineering, circular pipelines require high-precision cutting, which serves as the fundamental prerequisite for reliable maintenance and connection. To address the challenge of predicting the surface accuracy in the side milling of circular pipes, this paper proposes a geometric simulation algorithm for end mill side milling of circular pipes (SESC) based on the Z-map discrete grid method. The core of this algorithm comprises two parts: first, converting the continuous machined surface into a grid lattice through discretization and establishing a tool-workpiece contact judgment model based on the Z-map theory; second, constructing a tool trajectory transformation chain involving 6 sets of coordinate systems to achieve an accurate mathematical description of the complex motion trajectories of ordinary and serrated end mills within the annular enclosed space. Simulations are conducted based on SESC to systematically analyze the influence laws of the tooth profile parameters of serrated end mills, feed per tooth, tool deformation, and tilt angle on the surface topography, while revealing the unique side milling characteristics of serrated end mills. Side milling experiments with serrated end mills are carried out under different feed per tooth values. The results show that both the comparison between experimental and theoretical simulation results in terms of 3D geometric topography and the comparison of roughness results (with a maximum error of 14.26%) confirm the correctness of the SESC. This method provides an effective theoretical tool for the surface quality control of circular pipe side milling.