Reliability sensitivity analysis of ball-end milling accuracy

In the process of milling, the setting of parameters has a significant influence on the milling characteristics. If the selection of cutting parameters is not reasonable, it will be difficult to ensure the machining accuracy of the workpiece. Considering the uncertainty of cutting parameters in the milling process, this paper proposes a reliability sensitivity analysis method for angular ball-end milling precision. First, the cutting edge contact section is determined by the discrete event simulation, based on the Z-map method. Then, the milling cutter is considered equivalent to a cantilever beam, while a flexible prediction model, including the tool deformation in the milling process, is established. In order to improve the calculation efficiency of the tool deflection error, the functional relationship between the parameters and the machining error is reconstructed, using kriging technology. Following, the kriging model is used to replace the dynamic model to analyze the reliability sensitivity of milling precision, based on the Monte Carlo method. Finally, both experimental and simulation results show that the tool deflection error model and the sensitivity calculation method, as proposed in this paper, exhibit high precision.