Abstract
It has been noted that the deflection of the end mill and workpiece produced by the cutting force is a main cause of surface error in the end milling process. Because of the deflection, the surface error becomes even worse in the case of inside cornering cut. To improve machining accuracy, a predictive analysis on the behavior of the cutting force is performed indirectly by means of chip area. Based on the analysis, cutting methods with decreased axial depth of cut and improved shape of the machined surface in the preceding cut are proposed. Also, constraint adaptive control is considered against the rapid variance of cutting force. Through machining experiments, the effectiveness of the cutting methods and the adaptive control in decreasing the surface error in the corner is ascertained.
