Machining error correction based on predicted machining error caused by elastic deflection of tool system

A machining error correction, which is based on the predicted machining error caused by elastic deflection of tool system, is proposed. This method is based on an instantaneous force with static deflection feedback model which is classified to consider the milling process representation. The uncut chip thickness, which is required to predict cutting force, is calculated under the consideration of the elastic deflection of the tool system, which corresponds to tool and tool holder deflections caused by cutting force. In our previous study, the uncut chip thickness is calculated from voxels removed by each minute tool rotational angle, and the instantaneous cutting force in a minute time interval can be predicted. Furthermore, in our previous study, the elastic deflection of the tool system caused by the predicted instantaneous cutting force can be calculated. This study proposes the method to correct the tool position and posture according to the predicted horizontal displacement and the rotational displacement derived from the elastic deflection of the tool system. In order to validate the effectiveness of the proposed algorithm, the experimental milling operations were conducted. The experimental results showed that the successful error corrections can be performed. The correction of the tool position and posture according to the predicted elastic deflection of the tool system can achieve the improvement of machining accuracy and efficiency. © 2019 Japan Society for Precision Engineering. All rights reserved.