Statistical Modelling of Machining Error for Model-Based Elastomer End-Milling

Elastomer end-milling has attracted attention for use in the small-lot production of elastomeric fragments because the technique is an applicable method for a large variety of materials and does not require the preparation of expensive and time-consuming moulds. In order to effectively utilize elastomer end-milling, it is necessary to ensure the machining accuracy of elastomeric parts machined through this technique. However, the control method of machining error in the elastomer end-milling has not been presented since most machining services of the elastomeric part are based on enterprise-dependent dexterities or know-how. The objective of this paper is to construct and utilize a machining error model for elastomer end-milling. A statistical model based upon physical states and machining conditions is introduced and investigated. In this paper, a framework for modelling the machining error in elastomer end-milling is also proposed. In the framework, the candidates of model variables are evaluated based on the preliminary experiments. Moreover, a statistical model is constructed by using the selected variables. Candidate variables are cutting conditions and predictable physical state variables such as workpiece deformation and cutting force. The framework is investigated by evaluating error prediction with the experimental results. An identified error model from limited machining cases can estimate the machining error of different machining cases. The results indicate that the proposed modelling method is capable of supporting to achieve model-based precision elastomer end-milling.