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The purpose of this study is a real-time compensation of the machining error caused by deflection of a small diameter end-mill at a cutting point. Then, the growth mechanism of machining errors in end-milling was investigated by comparing measured deflection of tool and cutting forces with machining errors. As a result, it was found in the experiments that relation between deflection of tool at cutting point and normal force under cutting process could be estimated from static stiffness. In addition, it was concluded that machining errors in up milling could be estimated from minimum value of distance from cutting edge to ideal machined surface.

Monitoring of Machining Error Caused by Deflection of End-Mill Using Indirect Methods