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Prediction of Tool Deflection in Ball-end Milling Process  

Lee Kyo-Seung (경기공업대학 자동차학과)
Namgung Jae-Kwan (서울산업대학교 기계설계자동화공학부)
Park Sung-Jun (삼성전기 중앙연구소)
Publication Information
Transactions of the Korean Society of Machine Tool Engineers / v.14, no.3, 2005 , pp. 8-15 More about this Journal
Abstract
A new measuring method for tool deflection has been developed when sculptured surface is processed in ball-end milling. Since the vibration due to cutting forces has low frequencies, an electromagnetic sensor is used for measuring the exact vibration displacement. The amplitude and direction of vibration displacement during the cutting process is presented as orbital plot. In this study, it assumes that the vibration displacement is proportional to the length of cutting chip. Therefore, tool deflection is calculated by summing up the vibration displacement of unit chip length for engaged chip length. In addition, computer programs has been developed to predict the deflection of tools when machining sculptured surface. This developed program predicts the tool deflection per block of NC data, so that it can easily identify the parts which have the possibility of machining errors.
Keywords
Sculptured surface; Milling; Tool deflection; Orbital plot; finite cutting edge; Z-map;
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