Prediction of Machining Error Caused by Deflection of Ball End Mill (1st report)

Prediction of Machining Error in milling of inclined surface by dynamic cutting simulation

Abstract

Dynamic cutting simulation that calculates cutting force, tool vibration, and machined surface profile was developed to predict machining error caused by dynamic deflection of ball end mill. Simulation model includes the process damping force due to contact of cutting edge with workpiece. Unknown cutting parameters, which are coefficients of cutting force and process damping force, were estimated by minimizing the sum of squared deviations between calculated cutting forces and tool vibrations and measured ones. The predicted machining errors by using these parameters are good agreement with the results of cutting experiments of inclined surface with a long ball end mill under a wide range of spindle speed, where it is difficult to predict machining errors by static deflection model.