Research On Modeling And Compensation Of Machining Error Induced By Tool Wear

With the development of aviation manufacturing industry, machining precision has been more andmore important for workpiece. While the existence of machining error will directly influence thesurface quality and accuracy of the workpiece, or even make the workpiece useless, so predicting themachining error and make compensation for it has important theoretical significance and applicationvalue. In this paper, theoretical analysis and experiment method have been used to study themachining error in ball-end milling of difficult-to-cut materials. The main achievements are asfollows:1. After obtaining the tool wear by using shape-mapping method, the wear model of ball-end toolmilling stainless steel was established The variation of the the cutting edge profile between theoriginal tool and the worn one was studied on the basis of tool wear model, then the machining errormodel was built according to the theoretical analysis of cutting edge profile.2. Based on the established machining error model, a new method for compensating the machineerror was put forward to determine the compensation value at any point of the workpiece. Themachining error can be compensated through reverse revising the cutting tool to a certain position,and the compensation process for milling plane and arc surface was analysed. With Visual C++6.0development tool, software modules of machining error compensation were developed by which thenew NC files could be generated for milling.3. A series of machining experiments had been designed by using ball-end cemented carbidescutting tool milling stainless steel0Cr18Ni9. With CMM and LEICA DVM5000microscope, thequality of the workpiece surface was detected. Experimental results validated the correctness of theerror model and the effectiveness of the compensation.4. Based on the analysis of the variation of the the cutting edge profile after tool wear, the millingtrajectory model of the cutting edge was established by considering the influence of tool wear and anew simulation algorithm was designed to obtain the locus which was forming the surface topography,so that the surface topomorphy of the milled workpiece could be predicted.