Abstract
By using a cutting model and energy method proposed in previous papers, cutting forces in milling processes in which both cutting edges of spherical and cylindrical portions engage with the workpiece can be predicted. In the 2nd part of this investigation, the tool deflection and locus of tool axis during milling were analyzed by using the cutting force data predicted and the FEM model of a ball end mill. Tool deflection and behavior of the tool axis during contour milling of inclined surfaces ware measured by using an eddy-current type sensor and compared with the predicted results. In this report, geometrical configurations of the machined surface and the machining errors obtained through the analysis of tool deflection are shown for various slopes of the inclined surface. It is found that machining errors disagree with the magnitudes of deflection of the tool axis in a plane normal to the feed direction, so the errors can′t be evaluated by neglecting the condition of cutting edge engaged with the workpiece such as rotational angle and tool geometry.
