Title: Compensation of a ball end tool trajectory in complex surface milling

Authors: M. Smaoui; Z. Bouaziz; A. Zghal; M. Baili; G. Dessein

Addresses: Unit of Mechanics, Solids, Structures and Technological Development, Ecole supérieure des sciences et techniques, BP 56 Beb Mnara, 1008 Tunis, Tunisia. ' Unit of Mechanics, Solids, Structures and Technological Development, Ecole supérieure des sciences et techniques, BP 56 Beb Mnara, 1008 Tunis, Tunisia. ' Unit of Mechanics, Solids, Structures and Technological Development, Ecole supérieure des sciences et techniques, BP 56 Beb Mnara, 1008 Tunis, Tunisia. ' Ecole Nationale d'Ingénieurs de Tarbes, Laboratoire Génie de Production, Université de Toulouse, INP/ENIT, LGP, 47 avenue d'Azereix, BP 1629, F-65013 Tarbes Cedex, France. ' Ecole Nationale d'Ingénieurs de Tarbes, Laboratoire Génie de Production, Université de Toulouse, INP/ENIT, LGP, 47 avenue d'Azereix, BP 1629, F-65013 Tarbes Cedex, France

Abstract: This work is consecrated to the minimising of machining errors based on a method for the compensation of the trajectory to be machined in hemispherical milling. This compensation is found to be necessary because of the tool deflection due to the cutting forces. In order to remedy to the machining errors, caused by this deflection, a compensation method has been proposed. The latter is inspired from the mirror method, since the compensated position is going to be determined as being the trajectory reflection, deviated onto the mirror. The advantage of this proposed method is that it takes into account the three deflections d_x, d_y and d_z, respectively to the directions X, Y and Z. After that, two-parallel machinings, separated by a groove and achieved absolutely in the same conditions and with the same tool, are carried out, on the same complex part. The first machining is with compensation, but the second is without compensation. The coordinates of the two obtained surfaces are recorded by a 3D measuring machine. The comparison of the two-surfaces shows the presence of an important correction of the tool trajectory, and reveals a similarity between the part obtained by simulation and the one conceived in CAM.

Keywords: ball end milling; cutting forces; tool deflection; cutting force; ball end tool trajectory; complex surfaces; trajectory compensation; simulation.

DOI: 10.1504/IJMMM.2012.044923

International Journal of Machining and Machinability of Materials, 2012 Vol.11 No.1, pp.51 - 68

Received: 06 Jul 2010
Accepted: 25 Nov 2010
Published online: 23 Aug 2014 *

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