Improved Analysis of the Workpiece Accuracy in Turning, Based on the Emerging Diameter

Improved formulation of a workpiece deflection, accounting for the progressively increasing compliance due to the reduced diameter which emerges during turning, was developed and used to evaluate the deflection and its effect on machining error through computer simulation. The results demonstrate that when considering the moving step in diameters, the effect of depth of cut becomes more pronounced for slenderness L/D>6, It was revealed that the maximum deflection occurs either at the tailstock for lower slenderness or at approximately 0.6L from the spindle for higher slenderness. As the new formulation ensures more accurate prediction of the machining error, a nondimensional procedure generalizing the results is provided for practical applications.