Determination of Tool Deflection Compensation for Finish Machining of T6061 Aluminium Alloy In 3-Axis CNC Vertical Milling Operation Using Ball End Milling Tool

Abstract

In end-milling operations, especially for machining of sculptured surfaces when the ball-end milling cutter has very high length to diameter ratio, the tool has got the tendency to deflect sideways even when nominal cutting force is acting on the tool. This deflection of tool should be calculated and compensated before performing actual machining operation. Various methodologies have been discussed in this whole work regarding tool deflection calculation and compensation. Out of all those methodologies, any suitable methodology can be selected where tool shape can be studied in more realistic form. Using Kim et al. [2] methodology, tool deflection has been calculated. The approach proposed by Chiang et al. [1] has been used for cutting force determination in case of ball-end milling cutter. Then mirror method has been used for tool deflection compensation. Machining of slots has also been done using ball-end milling cutter to compare both compensated and non-compensated toolpaths. Ball-end milling cutters are mostly used for finish machining operation of complex sculptured surfaces because they provide better surface finish along feed direction and also produce minimum number of feed-marks. Moreover, it has also been observed that toolpath applied with compensation using mirror method is very close to the ideal one. The Literature review and results and discussions portion related to tool deflection and compensation has also been discussed in the subsequent chapters.