Abstract
In this study, a quasistatic force-deflection interaction model considering cutting and elastic force was proposed to analyze and compensate for the quasistatic deflection of slender ball-end milling cutter. The theoretical waveforms and peaks of cutting force considering the force-deflection interactions were consistent with the experimental results. The deflection of slender ball-end milling cutter significantly reduces the cutting force, and the Pearson's correlation coefficient between the difference in the peak cutting force and maximum deflection in radial is larger than that of in feed directions. An analysis of the machining error of a cylindrical surface revealed that the deflection of slender ball-end milling cutter had a considerable effect on the machining error, and the compensation of slender cutter deflection effectively reduced the amplitude and fluctuation of the machining error. This work can provide a useful guidance for machining error control in the ball-end milling process of mold surfaces with deep cavities.
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