Real-Time Estimation of Machining Error Caused by Vibrations of End Mill

The purpose of this study is to establish a method of estimating, in real time, the machining error caused by vibrations of the cutting point of an end mill. The vibration displacement at the shank of the end mill and the dynamic cutting force were measured during cutting tests while spindle speed was increased from medium to high. It was found that the vibration displacement at the cutting point at the moment when the radial direction of the cutting edge is normal to the feed direction showed a good agreement with the height of the machined surface at a spindle speed of 4500 rpm or less.