Force Feedback Control of Tool Deflection in Miniature Ball End Milling
نویسندگان
چکیده
Injection molding is an important manufacturing process for optical and mechanical components. The hard steel dies used in this process play a direct role in the quality of molded parts. Traditionally, fabricating these dies involved rough milling followed by heat treatment, grinding, and polishing to the desired shape. Recently, high-speed machining of heat-treated steel (hardness > 55 Rc) has become a viable approach for reducing fabrication times while retaining the necessary shape control. However, as feature sizes drop below 1 mm with dimensional tolerances on the order of 10 μm, tool deflection can create significant errors in the shape of mold surfaces. Deflections associated with miniature ball end tools can exceed 30 μm, rendering finished dies out of tolerance.
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