Two-Axis Force Feedback Deflection Compensation of Miniature Ball End Mills

Abstract

The primary objective of this research is to improve dimensional tolerances and reduce total manufacturing time of precision milling operations through the implementation of force-feedback machining. Force-feedback machining consists of using real-time cutting force measurement integrated with high bandwidth actuation to provide active error compensation of tool deflection. This research focuses on the development and implementation force-feedback machining using miniature (< 1 mm diameter) ball end mills. Due to the thin geometry of these tools, deflection of the tool during machining results in significant form error of the machined part. A piezoelectric two-axis force feedback actuator was designed and developed to measure and compensate for tool deflection errors of miniature ball end mills. Geometric form error was reduced by 75 % thru the application of force feedback machining.