Studying the influence of the machining process on the geometrical defects of the standardized S-shape test part

Abstract

In 2020, an S-shape part was proposed as a 5-axis reception test part in the new version of ISO 10791–7:2020. This test part enables the testing of machine-tool behavior that involves a high variation in tool axis orientation. This test part is formed of an S-shape fillet which is machined in flank milling with an endmill of Ø20 mm. Any defects of the machined part are influenced by the accuracy of the CAD model, the CAM tool path computation, the measurement uncertainty of the free-formed surface by a coordinate measurement machine (CMM), and machine-tool geometric behavior. This article aims to quantify the influence of all these steps on the final defects of machined parts. The proposed conclusion to our work is based on analytical and numerical study and experimental analysis. Finally, we propose an identification process for machine-tool architecture geometrical defects pertaining to the measurement of the machined S-shape part.