Modeling and wear-induced error compensation of ball-end milling cutter wear

Abstract

The measure mode of wear is proposed for ball-end milling cutter and tool wear model is built. Tool wear model coeffi-cients are decided to use tool wear data measured by mapping mode in ball-end milling cutter. Various experimental works have been performed to verify the validity of the proposed tool wear model. It is shown that the proposed model is capable of accurate prediction tool wear of ball-end milling cutter. At the same time, the algorithm of off-line simulation error compensation is proposed for wear-induced error of ball-end milling cutter. The algorithm predicts the machining error for one tool move using the proposed tool wear model in the NC mill machining and acquires one tool move of over tolerance. The NC programs are modified prior to practical machining operations for one tool move of over tolerance. The error compensation experimental results verify the validity of the proposed algorithm of off-line simulation error compensation and show that the error compensation algorithm is satisfying.