In an effort to reduce machining surface errors due to tool deflection in the end milling process, methods regulating cutting forces have been implemented with online feed rate controls. Such schemes are able to improve the parts dimensional accuracy, but unfortunately they can exhibit undesirable aspects in which the alleviation of the cutting conditions deteriorates the productivity. In addition the frequent changes of the feed rate would spoil the surface quality. As a new approach to achieve the precision machining efficiently, this paper introduces a tool deflection compensation system. This compensation system is a computer controlled special tool adapter which is capable of measuring the cutting forces and minutely adjusting the position of the tool without interfacing with the NC controller of the milling machine. Such a system allows for on-line estimation of the tool deflections and reduction of the surface errors. Experimental investigations for typical shaped workpieces representing various end milling situations are performed to verify the ability of the system to suppress the surface errors due to tool deflections in more productive machining condition.
Issue Section:
Research Papers
Topics:
Deflection,
Milling,
Cutting,
Errors,
Machining,
Computers,
Control equipment,
Milling machines,
Surface quality
1.
Altintas
Y.
1994
, “Direct Adaptive Control of End Milling Process
,” Int. Mach. Tools Manufact.
, Vol. 34
, No. 4
, pp. 461
–472
.2.
Altintas
Y.
Yellowley
I.
1987
, “The Identification of Radial Width and Axial Depth of Cut in Peripheral Milling
,” Int. Mach. Tools Manufact.
, Vol. 27
, No. 3
, pp. 367
–381
.3.
Armarego
E. J. A.
Deshpande
N. P.
1991
, “Computerized End-Milling Forces Predictions with Cutting Models Allowing for Eccentricity and Cutter Deflections
,” Annals of the CIRP
, Vol. 40
, No. 1
, pp. 25
–29
.4.
Ber
A.
Rotberg
J.
Zombach
S.
1988
, “A Method for Cutting Force Evaluation of End Mills
,” Annals of the CIRP
, Vol. 37
, No. 1
, pp. 37
–40
.5.
Budak
E.
Altintas
Y.
1994
, “Peripheral Milling Conditions for Improved Dimensional Accuracy
,” Int. Mach. Tools Manufact.
, Vol. 34
, No. 7
, pp. 907
–918
.6.
Elbestawi
M. A.
Mohamed
Y.
Liu
L.
1990
, “Application of Some Parameter Adaptive Control Algorithms in Machining
,” ASME Journal of Dynamic Systems, Measurement, and Control
, December, Vol. 112
, pp. 611
–617
.7.
Kline
W. A.
Devor
R. E.
Lindberg
J. R.
1982
, “The Prediction of Cutting Forces in End Milling with Application to Cornering Cuts
,” Int. J. Mach. Tool Des. Res.
, Vol. 22
, No. 1
, pp. 7
–22
.8.
Kline
W. A.
Devor
R. E.
Shareef
I. A.
1982
, “The Prediction of Surface Accuracy in End Milling
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, August, Vol. 104
, pp. 272
–278
.9.
Kolarits
F. M.
DeVries
W. R.
1991
, “A Mechanistic Dynamic Model of End Milling for Process Controller Simulation
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, May, Vol. 113
, pp. 176
–183
.10.
Liang
S. Y.
Perry
S. A.
1994
, “In-Process Compensation for Milling Cutter Runout via Chip Load Manipulation
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, May, Vol. 116
, pp. 153
–160
.11.
Matsubara
T.
Yamamoto
H.
Mizumoto
H.
1987
, “Study on Accuracy in End Mill Operations (1st Report)—Stiffness of End Mill and Machining Accuracy in Side Cutting
,” Bull. Japan Soc. of Prec. Engg.
, Vol. 21
, No. 2
, June, pp. 95
–100
.12.
Matsubara
T.
Yamamoto
H.
Mizumoto
H.
1987
, “Study on Accuracy in End Mill Operations (2nd Report)—Stiffness of End Mill and Machining Accuracy in Side Cutting
,” Bull. Japan Soc. of Prec. Engg.
, Vol. 25
, No. 4
, Dec, pp. 291
–296
.13.
Milner
D. A.
1974
, “Controller System Design for Feedrate Control by Deflection Sensing of a Machining Process
,” Int. J. Mach. Tool Des. Res.
, Vol. 14
, pp. 187
–197
.14.
Oraby
S. E.
Hayhurst
D. R.
1990
, “High-Capacity Compact Three-Component Cutting Force Dynamometer
,” Int. Mach. Tools Manufact.
, Vol. 30
, No. 4
, pp. 549
–559
.15.
Sim
C. G.
Yang
M. Y.
1993
, “The Prediction of the Cutting Force in Ball-End Milling with a Flexible Cutter
,” Int. Mach. Tools Manufact.
, Vol. 33
, No. 2
, pp. 267
–284
.16.
Smith
S.
Tlusty
J.
1991
, “An Overview of Modeling and Simulation of the Milling Process
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, February, Vol. 113
, pp. 169
–175
.17.
Sutherland
J. W.
Devor
R. E.
1986
, “An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, November, Vol. 108
, pp. 269
–279
.18.
Tani
Y.
Hatamura
Y.
Nagao
T.
1983
, “Development of Small Three-component Dynamometer for Cutting Force Measurement
,” Bulletin of the JSME
, Vol. 26
, No. 214
, April, pp. 650
–658
.19.
Tarn
J. H.
Tomizuka
M.
1989
, “On-Line Monitoring of Tool and Cutting Conditions in Milling
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, August, Vol. 111
, pp. 207
–212
.20.
Tarng
Y. S.
Cheng
S. T.
1993
, “Fuzzy Control of Feed Rate on End Milling Operations
,” Int. Mach. Tools Manufact.
, Vol. 33
, No. 4
, pp. 643
–650
.21.
Watanabe
T.
Iwai
S.
1983
, “A Control System to Improve the Accuracy of Finished Surfaces in Milling
,” ASME Journal of Dynamic Systems, Measurement, and Control
, September, Vol. 105
, pp. 192
–199
.22.
Yang
M. Y.
Park
H. D.
1991
, “The Prediction of Cutting Force in Ball-End Milling
,” Int. Mach. Tools Manufact.
, Vol. 31
, No. 1
, pp. 45
–54
.23.
Yang
M. Y.
Sim
C. G.
1993
, “Reduction of Machining Errors by Adjustment of Feedrates in the Ball-End Mill Process
,” Int. J. Prod.
, Vol. 31
, No. 3
, pp. 665
–689
.24.
Yazar
Z.
Koch
K. F.
Merrick
T.
Altan
T.
1994
, “Feed Rate Optimization Based on Cutting Force Calculations in 3-Axis Milling of Dies and Molds with Sculptured Surfaces
,” Int. Mach. Tools Manufact.
, Vol. 34
, No. 3
, pp. 365
–377
.
This content is only available via PDF.
Copyright © 1998
by The American Society of Mechanical Engineers
You do not currently have access to this content.
