Machining Accuracy Due to Tool or Workpiece Vibrations

This paper presents a newly developed method for predicting dimensional errors caused by vibrations of either the cutting tool or workpiece. In previous literature, this phenomenon has been described as the “surface location error” from process dynamics. Analytical predictions are compared to several milling experiments: 1) a flexible workpiece and rigid tool; and 2) a rigid workpiece and flexible tool. Tool or workpiece vibrations were measured with non-contact sensors during the cutting process. In addition, dimensional errors were directly measured on machined parts. The results from experimental cutting tests show good agreement with theoretical predictions.