Deviation of a machined surface in flank milling

The flatness defects observed in flank milling with cutters of long series are mainly due to the tool deflections during the machining process. This article present the results of an identification procedure of the coefficients of a force model for a given tool workpiece couple for the prediction of the defects of the tool during the cutting. The calibration method proposed meets a double aim: to define an experimental protocol that takes the industrial constraints of time and cost into account and to work out a protocol which minimizes uncertainties likely to alter the interpretation of the results (environmental, software or mechanical uncertainties). For that, the procedure envisages the machining of a simple plane starting from a raw part formed by a tilted plane, allowing for the variation of the tool engagement conditions. The tool deviation during the cutting process is indirectly identified by measuring the machined surface. The observed straightness defect conditions can be explained by the evolution of the cutting pressures applied to the cutting edges in catch during the cutter rotation. The precision was considerably improved by the taking into account of the cutter slope defect in the calculation of the load applied to the tool. After identification of the tool-workpiece couple, the prediction model was applied to some examples and allowed to determine the variations of form and position of the surface points with a margin of 5%. (C) 2002 Elsevier Science Ltd. All rights reserved.