Enhancement of Machining Accuracy Based on Prediction of Tool Deflection Considering Feedrate Change of Machine Tools

Abstract

High-speed and high-accuracy machining are essential requirements to improve production efficiency for machine tools. However, in computer numerical control machine tools, the actual feedrate is different from the commanded value due to the control of feedrate change of machine tools, which reduces machining accuracy. In addition, tool deflection caused by the cutting force applied on the tool has a great influence on dimensional accuracy and the shape of the machined surface. Therefore, in this study, we modeled the actual feedrate change considering acceleration/deceleration processing of the machine tool, and proposed a method for improving the toolpath accuracy based on the modeling method. Furthermore, we also proposed a method to improve machining accuracy based on the prediction of the cutting force and tool deflection error for square-end mill tools considering the feedrate change. The experiment results confirmed the usefulness of the proposed method.