Error compensation in high-speed milling of deep cavity dies and molds based on the lengthened shrink-fit holder

Abstract

Background: In high speed milling of the dies and molds characterized by large-scale and deep cavities with the lengthened shrink-fit holder (LSFH), the machining error caused by the tool deflection is not allowed to be ignored. Methods: The deformation of the LSFH and cutting tool are predicted, and at the same time the machining error caused by this deformation are predicted too based on the milling force prediction model and the finite element model. Taking into account the complex mutual coupling between milling force and the deformation, an error compensation method is proposed based on a balancing iterative algorithm. Results: The compensation tool path is obtained and the off-line machining error compensation is achieved. Milling example shows that the machining error after compensation less 77.4 % than that of no compensation.Conclusions: The results demonstrate that the proposed error compensation method is reasonable and can greatly reduce the machining error.