Fly cutting surface profile mathematical model using kinematic motion errors and cutting parameters

This paper presents fly cutting surface profile mathematical model using the spindle and guideways kinematic motion errors, as well as cutting parameters. Surface residual height model was firstly established using the feeding velocity, cutting spindle rotational speed and tool tip radius, it indicates that the cutting depth will not affect the surface geometric profile. Surface profile dispersion was carried out using cutter spindle rotation speed and guideways feeding velocity parameters. Guideways kinematic motion errors were introduced into the surface profile model through overlying method, and cutter spindle axial runout error was also introduced by filtering process using filtering convolution operations between the tool tip window filter and guideways kinematic overlapped surface profile. Their mathematical model expressions and illustrations were given, respectively. They were coherent with the cutting experiments results. The proposed model could be used for the surface profile prediction and machine tool error budget.