151610 20260302074104.0 doi 10.1016/j.advengsoft.2025.103909 sideral 143228 ART-2025-143228 eng (orcid)0009-0004-1650-3670 Zekalmi, Yasser Universidad de Zaragoza New fast micro-topography estimation algortihms for 5 axis milling 2025 Accurately predicting the topography of machined surfaces is vital in industries like aerospace, automotive, and biomedical manufacturing. This paper introduces a novel methodology for fast and precise areal surface microtopography prediction in 5-axis CNC milling, particularly for finishing processes using ball-end milling tools. Although commercial CAM software can predict the macro-topography of a machined surface, incorporating the cutter edge geometry and its rotational movement is essential for accurately predicting the surface’s microtopography. In this work, three alternative algorithms based on the Z-Map method are proposed: (1) a parallelized version of Z-Map (MOD1) for increased computational efficiency, (2) a swept surface technique (MOD2) for more accurate simulations, and (3) a rounding technique (MOD3) for rapid, precise topography prediction by aligning cutter edge points. The user can choose one of the three algorithms based on computational resources and preferences. These are validated through experimental tests on a 5-axis milling machine under different machining conditions. The results demonstrate that the developed algorithms enhance the prediction of the machined surface’s micro-topography, significantly reducing computation time and improving accuracy compared to the traditional Z-map method info:eu-repo/grantAgreement/ES/DGA/T56-23R info:eu-repo/grantAgreement/ES/UZ/JIUZ-2023-IA-01 info:eu-repo/semantics/openAccess All rights reserved http://www.europeana.eu/rights/rr-f/ info:eu-repo/semantics/article info:eu-repo/semantics/publishedVersion (orcid)0000-0003-4839-0610 Albajez, José Antonio Universidad de Zaragoza (orcid)0000-0001-8689-6482 Aguado, Sergio Universidad de Zaragoza (orcid)0000-0001-8055-9362 Oliveros, María José Universidad de Zaragoza 5002 515 Universidad de Zaragoza Dpto. Ingeniería Diseño Fabri. Área Ing. Procesos Fabricación 205 (2025), 103909 [15 pp.] Adv. eng. softw. ADVANCES IN ENGINEERING SOFTWARE 0965-9978 18460424 http://zaguan.unizar.es/record/151610/files/texto_completo.pdf Versión publicada info:eu-repo/date/embargoEnd/2026-03-02 2671388 http://zaguan.unizar.es/record/151610/files/texto_completo.jpg?subformat=icon icon Versión publicada info:eu-repo/date/embargoEnd/2026-03-02 oai:zaguan.unizar.es:151610 articulos driver 2026-02-10-08:20:31 ARTICLE