IMPROVEMENT OF SURFACE WAVINESS BY CUTTING FORCE CONTROL IN MILLING

Abstract

To improve the surface waviness in peripheral milling, the feedrate was controlled so that the cutting force measured in the normal direction to the workpiece was constant. A discrete time first order model between the feedrate and the tool deflection was derived with consideration for the machine tool compliance. The model was used for the feedrate control by a fixed gain proportional plus integral (PI) controller. It has been shown by analysis that the tool deflection is directly related to the feedrate and that the tool deflection greatly affects the surface waviness during cutting. The experimental results show that the surface waviness was drastically reduced by the proposed method.