| Summary: | In order to optimize machined surface topography, this paper presents a novel algorithm for simulating the surface topography and predicting the surface roughness of a ball-end milling process. First, a discrete workpiece model was developed using the Z-map method, and the swept surface of a cutter edge was represented using triangular approximation. The workpiece surface was updated (i.e., material removal process) using the intersection between the vertical reference line and the triangular facet under a cutting judgement. Second, the proposed algorithm was verified by comparing the simulated 3D surface topography as well as 2D surface profile and average roughness (<i>Sa</i>) with experimental measurements. Then, numerical simulation examples planed by the Box–Behnken design methods were carried out to investigate the <i>Sa</i> in the ball-end milling operation. The correlations of <i>S<sub>a</sub></i> and cutting parameters were represented by a response surface reduced quadratic model based on the ANOVA results. Finally, the feed per tooth, radial depth of cut, and tilt and lead angles were optimized for improving the machining efficiency under the <i>Sa</i> constraints. This study presents an effective method for simulating surface topography and predicting the <i>Sa</i> to optimize the cutting parameters during ball-end milling process.
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