Force and form error models for wavy surface in successive peripheral milling process

The successive peripheral milling process is commonly used to reduce the form error on the wavy surface caused by the cutting force-induced tool or work deflection. For such wavy surfaces, the radial depth of the cut, the engagement angle, and the chip load vary along the cutter axis. In this paper, an improved convolution force model and a tool deflection model for wavy surfaces in the successive peripheral milling process are presented. The effects of milling configuration on the cutting force, form error, and surface roughness in successive peripheral milling are studied. The models are validated by a series of machining experiments. The measurement results show that the milling configuration has a significant influence on the surface roughness of the finished part. A recommendation is given on how to allocate the radial depth of cut in successive milling to improve machined surface quality in terms of geometry accuracy and surface roughness.