Proposal of Concept for Robustly-High-Precision Finishing with Ball End Mill Focusing on Tool Geometries and Cutting Conditions

In most conventional ball end milling processes, the small surface that is cut the latest in every tooth period by the trailing cutting edge remains as the finished surface, while the other large surface is removed by the consecutive tooth or in the consecutive pick feed path. Hence, the static/dynamic displacement can grow, resulting in a large surface location error. In this research, a concept is introduced where the remaining small surface is finished before the displacements grow. Tool geometries and cutting conditions to realize this concept are clarified and proposed, and its effectiveness is verified analytically and experimentally.