Digital Twin for Final Generated Surface Dimensional Error Analysis at Tool Path Level in Contour Milling

Abstract

Surface errors in contour milling due to force induced tool deflections have a direct impact on the dimensional and geometrical accuracy of the finished part. In this sense, virtual manufacturing systems provide the capability to predict the errors generated at the final surface aiming to reduce production ramp-ups. Effects of working conditions on the surface error imprinted by the tool during a stable milling process along the whole tool path are studied at different radial and axial depths of cut. The developed process model was validated experimentally, showing good agreement in the prediction of the resulting dimensional surface error for when a single tooth is involved in the cut.