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Textured surfaces play a decisive role in the development of many advanced fields. This study describes a new strategy for efficiently machining textured surfaces with regularly aligned cutter marks on a certain surface using a ball-end milling technique. This technique is called triangular pyramidal patch division milling, and it divides the target surface into many small triangular pyramidal patches. Each patch is generated using a helical tool path that rounds the restructured triangular pyramidal patch with variable distances. With this method, regularly aligned dimples can be formed by controlling the cross feed, feed speed, spindle speed, number of teeth, and side length of patch. Because the tops of patches are on the target surface, they cover the whole surface for obtaining higher precision and better surface properties. To predict the state of dimple alignment on an entire freeform surface, a 3D simulator is derived from 2D simulation by using Pro/E, a software application. According to the simulation result, regularly aligned dimples can be generated on the freeform surface by selecting suitable machining conditions. When textured surfaces are machined using ball-end mill and machining center, triangular pyramidal patch division milling technique is a very effective method.

Generation of Regularly Aligned Dimples on Triangular Pyramidal Patches Using Patch Division Milling