Active integration of tool deflection effects in end milling. Part 1. Prediction of milled surfaces

Effect of direction of parameterization on cutting forces and surface error in machining curved geometries

“…(1)-(7) and can be substituted in Eqs. (8) and (9) to predict the force in a given interval. As discussed by Rao and Rao [13], the cutting forces in machining of straight geometry coincide with dynamometer measured forces but in case of machining curved geometries the measured force depends on the cutter location with respect to workpiece geometry as shown in Fig.…”

“…This is due to change of workpiece curvature which leads to the variation of process geometry [2]. Most of the past research work to predict tool deflection induced surface error is focused on machining straight geometry workpieces [1,[3][4][5][6][7][8][9]. Some researchers have also made an attempt to predict tool deflection induced surface error in transient situations like machining corners of a pocket [10,11] and in case of circular geometry [12].…”

Experimental Investigation in Micro Ball-End Milling of Hardened Steel

“…This size effect is well identified in micro-milling and strongly impacts the performance of the tool [4] and the surface generation [5]. The dimensional characteristics of these tools accentuate deflection [6] and dynamic instability [7]. When machining with micro-tools, it is often observed tool vibrations and cutting instabilities [8,9], usually gathered in chatter instability issues.…”

Identification of static surface form errors from cutting force distribution in flat-end milling processes

“…Wan and Zhang [7] developed a general approach to predict surface form errors in peripheral milling using finite element method. Dépincé and Hascoët [8] dealt with the prediction accuracy of the machined surface using a contact point method. Lee and Kim [9] presented an analytical model to predict the geometric characteristics of the side wall in cylindrical end milling.…”