Based upon a simple empirical model describing a relationship between the feedrate and the tool deflection, an on-line control strategy was developed to compensate for the machining straightness error of end milling process.
In order to minimize the machining straightness error in a single pass, first, the location error was compensated before machining by moving the milling bed in the direction perpendicular to the finished surface, and next, the waviness error was controlled through the feedrate manipulation, which was calculated based upon the tool deflection, measured surface error and identified guideway error. The surface error was directly measured by a gap sensor located in front of the end mill.
Repeatibility of the proposed control algorithm was proved by experiments, and resulting that machining straightness error could be suppressed up to 40% of the case of uncontrolled machining.
