In a machining operation, self-excited vibration called chatter resulting from the interaction of a workpiece, a tool, and a machine is limiting manufacturers in selecting cutting process parameters that give the desired surface finish at a higher material removal rate. Thisresearch paper aimed to add some control over its impact on surface roughness by establishing a simulation model of the surface topography. The simulation was done by incorporating time-domain simulation of the cutting process based on the theory of machine and Z-buffer geometrical modelling technique. Z-buffer modelling technique applied by representing the workpiece as a Z-buffer model and by discretely dividing the cutting-edge displacement along the tool path. The main purpose of the time domain simulation was to get information about the tool displacement relative to the workpiece along the tool path to conduct z-buffering.

The influence of chatter on surface roughness was investigated on floor end milling by selecting a different combination of depth of cut and spindle speed keeping the feed rate constant. The resulting surface roughness of the simulated surface was analysed and described quantitatively by taking the arithmetic mean height (Sa) and maximum height (Sz) as a candidate for a real surface roughness measurement. The simulated surface model results were compared to the experiment. The result obtained shows that surface simulation has the potential to predict chatter and surface roughness that can be used for surface finish control when selecting cutting process parameters.