Research about Elastic Mechanism of Error Generation in Ball End Milling based in Geometric Analysis

This paper clarifies the elastic mechanism of error generation in ball end milling. At first geometric influence of the tool orientation on the thickness of undeformed chip in the ball end milling is analized precisely. Not only the shape of undeformed chip but also its thickness varies according to the tool orientations. So the authors have established a model of the elastic deformation of the ball end mill caused by the cutting force. As the verification of this model, the authors developed the experimental method for measuring the machining error on inclined surface in any direction and the cutting force is measured in same time. The cutting force on these experiments and the simulated results support the influence of tool orientations. Through the experimental results, the relationship between the tool orientation and the machining error has been clarified. The influence of tool orientation on the machining error has been discussed too. Finally the simple equation has been proposed that decribes the r...