Abstract
The location and the size of a geometrically defected region in the side wall of a corner, which is generated during the flat end-milling process, are investigated through experiments and geometrical analysis. A corner with inner and outer surfaces is assumed to be made up of one arc-surface patch and two flat-surface patches. Based on the previous findings that the change of material removal per tooth affects the geometry of the end-milled side wall, it is expected that the geometrically defected regions are located around the corner when the tool is approaching and leaving the arc surface. In this respect, analytic models are proposed to predict the location and the size of a geometrically defected region, which are then validated via comparison with the experimental results.
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