Tool deflection and geometrical error compensation by tool path modification

Abstract Accuracy of CNC machined components is affected by a combination of error sources such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. Some of these errors can be decreased by controlling the machining process and environmental parameters. However other errors like tool deflection and geometrical errors that have a big portion of total error need more sophisticated solutions. Conventional error reduction methods are considered as low efficiency and human dependent methods. Most of recently developed solutions cannot fulfill workshop needs and are limited to research papers. In the present study, machining code modification strategy has been considered as an applicable and effective solution to enhance precise machined components. Appropriate tool deflection estimation model as well as geometrical error analyzing methods have been selected and complementary algorithms for compensation of these errors have been developed. Metal cutting process has been modeled in a 3D simulation environment and implemented in force/deflection calculations. A software has been developed to generate compensated tool path NC program by tracing the initial tool path and compensating deflection/geometry deviations. The new procedure developed in the present work has been validated by machining Spline contours. The results show that using the new method, accuracy of machined features can be improved by about 8–10 times in a single pass.