Monitoring of Machining Error Caused by Deflection of End-Mill using Indirect Methods

Abstract

In recent years, machining center has been used widely in metal mold manufacturing process. Since metal molds used for injection molding are complex and fine in form, long end-mills with a small diameter have to be used in metal mold machining process. Long end-mills with a small diameter deflect on a large scale at a cutting point due to cutting forces. The purpose of this study is to establish a method of in real time estimating machining errors caused by deflection of end-mill. For this purpose, the growth mechanism of machining errors caused by deflection in straight end-mill was investigated by comparing estimated value of deflection of tool using cutting force with each measured value of deflection of tool and machining error.