A Model for the Prediction of Surface Flatness in Face Milling

Abstract

This paper presents a new model for the prediction of surface flatness errors in face milling. The model includes the effects of machining conditions, elastic deformation of the cutter-spindle and workpiece-fixture assemblies, static spindle axis tilt and axially inclined tool path. A new method called equivalent flexibility influence coefficient method is used to compute the elastic deflection of the cutter-spindle and workpiece-fixture assembly at the points of cutting force application. Single insert and multi-insert face milling experiments are conducted to evaluate the predictive ability of the surface flatness model. A comparison of the model predictions and measurements shows good agreement. The influence of static spindle axis tilt on the surface flatness error is found to be very significant. It is shown that care needs to be exercised in comparing the model predictions based on elastic deflection of the machining system and spindle axis tilt with the surface flatness error measurements due to the fact that these measurements may be inflated by inclusion of the surface roughness.

Experimental verification of manufacturing error pattern and its utilization in form tolerance sampling

“…That is to say that the surface profile must be suitably quantified to simplify the selection of the number and locations for the initial data points. For this reason, parts are manufactured by end (peripheral) milling and face milling (fly-cutting), consistent with the surface error models developed in [14] and [15], respectively. The corresponding surface patterns are quantified and the error models of [14] and [15] are verified.…”

“…Balasubramanian and Raman [25] used these equations to calculate forces while comparing alternate tool paths in face milling path planning. Gu et al [15] presented a model to predict surface flatness error in face milling. The model includes the machining conditions, deflection of the cutter-spindle and workpiece-fixture, and static spindle axis tilt.…”

“…Here, a sampling methodology exploiting the knowledge of manufacturing surface pattern and using the search heuristics presented in [13] is proposed. End-milled 7075-T6 aluminum plates and face-milled cast iron plates are made as per the specifications given in [14] and [15], respectively. Surface patterns are quantified and the error models of [14][15] are experimentally verified in this paper.…”

“…End-milled 7075-T6 aluminum plates and face-milled cast iron plates are made as per the specifications given in [14] and [15], respectively. Surface patterns are quantified and the error models of [14][15] are experimentally verified in this paper. It is supposed that exact locations of manufacturing errors are often difficult to mathematically model.…”

A study of the influence of processing parameters and tool wear on elastic displacements of the technological system under face milling

“…Gu et al [28] presented a new model for predicting surface flatness errors of the face milling process. The model included the effects of machining conditions, elastic deformation of the cutter spindle and workpiece fixture assemblies, static spindle axis tilt, and axially inclined tool path.…”