Analysis of Tool Deflection and Mechanism of Surface Generation in Ball End Milling of an Inclined Surface (2nd Report):—On the properties of machined surface and machining error caused with tool deflection—

In the 1st part of this investigation, the analysis of tool deflection and locus of tool axis during ball end milling along a contour line was presented. In the paper, cutting force data predicted by using the cutting model proposed in a previous paper and the Finite Element Method were used for analyzing the deformation of a tool. In this paper, tool deflection in the milling of an inclined surface is measured under various slopes of the surface and compared with the predicted results. The predicted results agree with the measured results well enough. Geometrical configurations of the machined surface and the machining errors obtained from the analysis are shown for various slopes of the inclined surface. It is found that machining errors disagree with the magnitudes of deflection of the tool axis in a plane normal to the feed direction, so the errors can't be evaluated by neglecting the condition of cutting edge engaged with the workpiece such as rotational angle and tool geometry. The machining error caused by tool deflection becomes small for milling of an inclined surface where the left side of the feed direction is higher.