Experiment and Modeling of Vertical Milling Cutter Deflection Due To Cutting Forces

Abstract

The purpose of the study was to determine the end mill cutter deflection due to cutting forces which are developed because of different parameters like feed, speed and cutting speed. Firstly, cutting forces are measured by dynamometer during machining and then measurements of the profile of the slot on coordinate measuring machine are done. The results are validated by comparing the actual profile with the desired profile. The two other theoretical methods to obtain the cutter deflection are Bond Graph modeling and Finite Element Analysis (FEA). The theoretical results are validated with the experimental result. The predicted results from FEA and Bond Graph modeling are very close to the experimental study. Though the predictions from FEA and the experimental results are reasonably accurate, Bond Graph modeling is more preferable due to significantly less computational time and space.