Model based analysis of machining error in end milling operation.

Based on the fact that the major sources of the machining error in end milling operation are the deflection of the machine-tool structure including tool holder, end mill, and their connecting parts, the relation between these deflections and the machining error is formulated. According to this formulation, the instantaneous cutting force can be calculated by using an oblique cutting model and then the machining error and its individual error components can be analyzed. The results obtained are as follows: Cutting force calculated by using an oblique cutting model is close to the measured value. Machining error and its components can be predicted qualitatively and quantitatively for various cutting conditions. Error component due to the end mill deflection decreases when the cutting point approaches to the holder-end side. Deformation of the jointed part at the end mill-holder connection can not be neglected, and varies depending on the tool holder used.