An Approach of Estimating Machining Error by Heuristic Geometrical Rule in 5-Axis Ball-Nosed End Milling

Abstract

The objective of this study is to minimize the machining error by selecting the appropriate tool orientation at each cutter location of ball-nosed end mill for 5-axis machining. By the proposed method, the machining error can be estimated with use of a few kinds of geometric properties without any consideration of dynamics of cutting process, hence the estimation algorithm becomes simple. This is significant merit of this method. The equation to estimate the machining error includes several parameters which are determined in the heuristic manner. The prototype of estimation system has been developed based on the equation, and the estimation results can be obtained for various tool orientations. The results represent the tendency of the minimum machining error, but the estimation accuracy should be improved in the future work.