Surface error shape identification for 3-axis milling operations

In 3-axis milling operations the surface error caused by the tool/workpiece static deflection assumes a certain shape along the axial depth of cut. The error shape changes considerably according to the cutting strategy, tool geometry and cutting parameters. This paper presents a comprehensive method to identify all the types of surface error profile in down-milling, proposing dedicated analytical equations. This approach has been experimentally validated to assess its accuracy and limits. The results of this approach are meant to ease the surface error prediction and measurement by reducing the number of points to consider along the axial depth of cut.