Calibration of the cutting process and compensation of the compliance error by using on-machine probing

This paper addresses the compensation of cutting process related errors in order to improve the accuracy of manufactured parts. The compensation is a modification of the tool dimension and the tool path using on-machine probing data. A cutting depth distribution-based approach is proposed to calibrate the cutting process according to the on-machine probed error model. This approach is investigated in cases of both rigid and compliant parts. The calibration offset is estimated for the actual cutting conditions with and without a fitting process. In the case study, the offset varies from 12 to 17 μm for down milling at 6000 rpm spindle speed. The impact of the cutting speed is investigated. A rectangular profile was machined with and without compensation in down and up milling mode. The results show that the proposed approach is effective. The error is reduced from a maximum of 25 μm for down milling and 10 μm for up milling to 4 μm in both cases.

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