Tool deflection error of three-axis CNC milling machines, monitoring and minimizing by a virtual machining system

Virtual manufacturing systems carry out the simulation of manufacturing processes in digital environment in order to increase accuracy as well as productivity in part production. There are different error sources in machine tools such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. The errors due to tool deflection is caused by cutting forces and have direct effects on dimensional accuracy and surface roughness of the parts, efficient life of the cutting tool, holder and spindle. This paper presents an application of virtual machining systems in order to improve the accuracy and productivity of part manufacturing by monitoring and minimizing the tool deflection error. The tool deflection error along machining paths are monitored to present a useful methodology in 1 Corresponding author. Tel: +98 9121197997 Journal of Manufacturing Science and Engineering. Received September 08, 2015; Accepted manuscript posted December 31, 2015. doi:10.1115/1.4032393 Copyright (c) 2015 by ASME Ac ce pt ed Ma nu sc rip t N ot C op ye di te d Downloaded From: http://manufacturingscience.asmedigitalcollection.asme.org/ on 12/31/2015 Terms of Use: http://www.asme.org/about-asme/terms-of-use ASME, Journal of Manufacturing Science and Engineering 2 controlling the produced parts with regard to desired tolerances. Suitable tool and spindle can also be selected due to ability of the error monitoring. In order to minimize the error, optimization technique based on genetic algorithms is used to determinate optimized machining parameters. Free form profile of virtual and real machined parts with tool deflection error are compared in order to validate reliability as well as accuracy of the software.