High-Accuracy Machining of Thin-Walled Workpiece by Non-Rotational Tool-Analysis of Machining Accuracy Based on Deflection of Tool and Workpiece Using FEM-

In this paper, the FEM analysis and the machining of a workpiece using a non-rotational tool are attempted in order to produce a highly accurate surface on a thin wall. Also, the machining accuracy of the thin wall produced by the non-rotational tool is compared with that produced by an end mill. The main results are as follows. (1) FEM models for the tool and workpiece are made and the machining accuracy is predicted based on the deflection analysis using FEM due to the cutting force. (2) The tendency of the shape of machined surface is almost coincident with that of the predicted shape, so the propriety of the method of analysis is verified. (3) Both dimensional and shape error on the inside and outside surfaces of the workpiece produced by the non-rotational tool prove larger than the predicted values. Although the shape error proved a little larger than the predicted value, the target value of 5μm was achieved. (4) It is shown that the dimensional error due to under cutting decreases with the decrease in the radius of the tool edge. And also, on and after the second cutting process, the cutting at the commanded depth of cut was achieved even if the micro depth of cut.