Abstract
This study deals with new prediction method for cutting error caused by tool deflection and instantaneous cutting force in ball end milling. In conventional prediction systems, process models without consideration about influences of cutting edge roundness, ″elastic recovery″ and ″ploughing″, were widely used. However, in finishing process, workpiece surface is often generated at moment when actual depth of cut is smaller than cutting edge roundness. This fact means that cutting error prediction for finish machining is required to consider these phenomena. So, in order to realize accurate prediction of instantaneous cutting force, we have proposed the new prediction model focused the effects of cutting edge roundness in former studies. In this paper, we mention about new simulation algorithm to adopt the proposed model to ball end milling. We develop a new simulation procedure and conduct experimental machining in order to verify the proposed procedure.
