Improvement to High-Speed End Mill Boring Accuracy by a Simple Compensation Strategy (original) (raw)

In order to replace a boring bar process with high-speed end mill boring, an experimental approach is used to investigate the main sources of errors which affect circular contouring accuracy at different feedrates and trajectory radii for two types of machine tool of various guiding technologies and controllers. Results show that both machines exhibit radius size errors that are significant. They also show that backlash and reversal spikes are important sources of error which affect out-of-roundness. To reduce the out-of-roundness errors, backlash and reversal spikes were first compensated by fine tuning the indigenous controller compensation for those errors. Then, a simple experimental model based on statistical tests is developed and used to predict the radius size errors. The proposed model is then used to compensate the radius size errors during high-speed end mill boring. Two types of experiment are performed: boring with a boring bar and boring with a high-speed end mill.