Modeling flatness deviation in face milling considering angular movement of the machine tool system components and tool flank wear

The torsional angle, χYDeg, of a machine tool-device-spindle unit is formulated in a face-milling operation. As there is no angular compliance in the technical specifications for the machine tool, a novel method is proposed for the determination of the angular compliance values of a GF2171S5 machine milling system. Deviation from flatness, ΔZfl, is therefore also modeled in this paper, for the first time, by considering the parameters of milling and tool wear. The proposed model performs an acceptable evaluation of various types of flatness deviation for different flank wear values. The face milling and tool-wear parameters and their influence on the torsional angle of the tool-device-spindle unit are calculated. Besides, the effects of different settings on the machining process and the material-cutting speed vc and depth ap, cutting-edge angles kr, and tool slenderness-lo/D in combination with various depths of flank wear VB on the torsional angle of the mill χYDeg and flatness deviation ΔZfl are investigated. This method of determining the angular torsional values can be applied to other milling machines. Moreover, the model can be used to compensate the torsional angle of the mill face, thereby minimizing the flatness deviation.