Analysis on Prediction of Surface Error Based on Precision Milling Cutting Force Model

Abstract

High speed peripheral milling with solid tool is a critical machining process in modern aerospace manufacture industry. However, the surface error involving with tool deflection in milling limits the product precision and efficiency. In this research, the prediction of surface error is achieved with respect to precision milling force model and tool rigidity. Then the prediction coefficients are optimized involved with cutting speed and tool rake angle based on experiment data. And oblique cutting force model is approached transformed from orthogonal cutting force modal by equivalent rake angle, which is the understructure of milling force model. Furthermore, influence of tool deflection on thickness and range of cutting layer is considered as the feedback to the prediction of cutting force and surface error. Prediction model of tool deflection is achieved based on the equivalent diameter tool model and milling force model with respect to deflection superposition principle. Finally, prediction model of surface error and milling force is approached with the tool deflection as feedback. And the predicting precision is validated by peripheral milling experiment.