A new tool deformation compensation model considering the coupling of machining geometry and cutting force

Ruled surface machining is achieved through continuous moving cutting with a large axial depth, and the tool deformation error is inevitable. In this paper, a tool compensation model considering the coupling of cutting force and machining geometry is proposed for the five-axis side milling of a ruled surface with a flat end mill. This model focuses on the coupling relationship between cutting force, cutting geometry, and tool deformation. Firstly, the three analytical sub-algorithms are established, and the cyclic iterative method is used to solve the equilibrium state of tool deformation. Further, with the coincidence of the design surface and the machining surface as the constraint condition, the tool axis vector and radial cutting depth correction are gradually searched and calculated to achieve tool deformation compensation. The experimental results show that the maximum error after compensation is 0.0543 mm, the maximum error without compensation is 0.2853 mm, and the machining accuracy is improved by about 80.97%.