In this paper, a mechanistic model for surface generation in peripheral milling, which includes the effects of cutter vibrations, run out, as well as flank wear is presented. The surface roughness parameters, and characteristic features of the surface profile were examined using computer simulations. The results of the simulation runs were verified experimentally and a good agreement was obtained. The results demonstrated clearly the importance of including tool wear in surface generation predictions. It has been shown that the model is capable of predicting the smearing of the surface generated due to increased tool wear. Also, the ploughing force acting on the wear land considered in the model influenced the resulting profile error significantly.

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