Analysis of End Milling Surface Error Considering Tool Compliance

Abstract

An analytical model of surface height error in end milling due to the elastic compliance of cutting tool is presented. Based on the relationship of local cutting forces and chip thickness, the shear loading and bending moment on tool cross section are presented in terms of cutter angular position. The tool deflection responding to the bending moment is then established including the consideration of workpiece and machine tool structural deflection. The expression for surface error is derived as a closed-form function of the machining parameters, cutting configuration, material characteristics, and machine receptance.