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This paper proposes improving microgrooving system on an ordinary lateral milling machine by using controlled cutting with reference surface (CCRS). CCRS improves ultra-precision machining accuracy through in-process measurement and control. CCRS controls relative displacement between the tool and workpiece, effectively improving table motion error accuracy. CCRS was confirmed in simulation and experiments to (1) improve accuracy if digital control sampling time is enough shorter than the error motion period and (2) worsen surface roughness because the feed rate equals cutting speed in shaping if the shorter sampling time for the error motion period cannot be used. In other words, the relationship between improvement in table error motion accuracy and desirable surface roughness is a trade-off solved by using fly cutting with CCRS.

Figure Error Control for Microgrooving on Ordinary Lateral Milling Machines Using a Reference Surface to Control Cutting