Estimation of Machining Error Caused by Deflection of Tool Using Cutting Force in Ball End Milling of Inclined Surface

For a cutting process using a low-rigidity end mill, it is very important to be able to estimate the machining error caused by the deflection of the tool. The purpose of this study is to establish a method for the real-time estimation of the machining error caused by the deflection of the tool at the cutting point of a ball-end mill. The method was verified by comparing the estimated deflection and the machining error when milling an inclined surface. It was concluded that the machining errors in ball-end milling of inclined surfaces can be estimated from the normal force at the moment when the radial direction of the peripheral cutting edge is normal to the feed direction of the tool.