The invention relates to a surface
topography prediction method based on a ball-end cutter model and a variable step size iterative
algorithm, which is based on the ball-end cutter model, combines and applies a dynamic
variable time step size strategy, accurately divides
cutting and non-
cutting tracks, and remarkably improves the
simulation efficiency and precision. Through multi-coordinate
system dynamic modeling and a
specific function, the eccentricity of the ball-
end milling cutter is compensated, the abrasion is accurately modeled, dynamic physical
coupling is combined, the actual
machining state of the ball-
end milling cutter is accurately simulated, the
simulation precision and authenticity are improved, and the high-precision requirement of
aerospace parts can be met. Meanwhile, through
modular design, a complex curved surface
tool path is accurately simulated, and through adjustment of evaluation parameter threshold values, the method can be expanded to surface
topography prediction of various difficult-to-
machine materials, process parameters are rapidly iterated, and the
process optimization period is greatly shortened.