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In the end milling process, the cutting forces during machining produce deflection of the cutter and workpiece which result in dimensional inaccuracies or surface error on the finished component. A previously developed mathematical model for the cutting force system in end milling is combined with models for cutter deflection and workpiece deflection so that the surface error profile may be predicted from the machining conditions and geometry and material properties of the cutter and workpiece. Machining experiments are performed on rigid and flexible workpieces of 7075 aluminum to verify the ability of the models to predict surface error. The model predicted surface error profiles are accurate both in magnitude and shape with the difference between measured and predicted surface errors ranging from 5 to 15 percent. This approach for the prediction of surface errors provides a useful aid for the analysis of a variety of end milling process design and optimization problems.

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William D. Schindel is president of ICTT System Sciences, a systems engineering company, and developer of the Systematica Methodology for model and pattern-based systems engineering. His 40-year engineering career began in mil/aero systems with IBM Federal Systems, Owego, NY, included service as a faculty member of Rose-Hulman Institute of Technology, and founding of three commercial systems-based enterprises. He has consulted on improvement of engineering processes within automotive, medical/health care, manufacturing, telecommunications, aerospace, and consumer products businesses. Schindel earned the BS and MS in Mathematics.

is president of ICTT System Sciences, a systems engineering company, and developer of the Systematica Methodology for model and pattern-based systems engineering. His 40-year engineering career began in mil/aero systems with IBM Federal Systems, Owego, NY, included service as a faculty member of Rose-Hulman Institute of Technology, and founding of three commercial systems-based enterprises. He has consulted on improvement of engineering processes within automotive, medical/health care, manufacturing, telecommunications, aerospace, and consumer products businesses. Schindel earned the BS and MS in Mathematics.