Abstract
It has been noted that the deflection of the end mill and workpiece produced by the cutting force is a main cause of surface error in the end milling process. The deflection, therefore surface error, becomes even worse in the case of inner cornering cut. To improve machining accuracy, a predictive analysis on the behavior of the cutting force is performed indirectly by means of chip area. Based on the analysis, cutting methods with decreased axial depth of cut or improved shape of the finishing surface in the preceding cut are proposed. Also constraint adaptive control is considered for the rapid variance in cutting force. Through experiments, the effectiveness of the cutting methods and adaptive control in decreasing the error in the corner is acertained.
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