Form error estimation in ball-end milling of sculptured surface with z-level contouring tool path

This paper presents a flexible model for estimating the form error in three-axis ball-end milling of sculptured surface with z-level contouring tool path. At an interval of feed per tooth, the whole process of sculptured surface machining is treated as a combination of sequential small inclined surface milling. For ball-end milling of the inclined surface with z-level contouring tool path, at surface generation position, an analytical model is proposed to identify the feedback effect of tool deflection on cutting edge engagement. The deflection-dependent cutting edge engagement is determined by using an iterative procedure. And ultimately, the form error is obtained from the balanced tool deflection and associated surface inclination angle. In a validation experiment, the estimated form errors are compared with both the measurements and the predictions of a rigid model. It is shown that the proposed flexible model gives significant better predictions of the form error than rigid model. Good agreement between the predicted and measured form errors is demonstrated for the ball-end milling of sculptured surface with z-level contouring tool path.