Active integration of tool deflection effects in end milling. Part 1. Prediction of milled surfaces

Tools deflection that occurs during machining, and especially when flexible tools such as end mills are used, can result in dimensional errors on workpieces. The study presented here is part one of a two-part paper: it deals with the estimation of cutting forces and the prediction of milled surface. The second part will focus on a methodology that allows to optimize the production rate by compensating the deflection and meeting the part tolerance.Cutting force models have been and are still the subject of a lot of research. The model used is based on Kline and Devor's [5]: a polynomial approximation whose coefficients are obtained by least square methodology is used for the calculation of cutting forces. The machined surface (two axis machining) is determined using the contact point methodology and some experimental tests are done to validate the models.