Real-time measurement of milling tool behavior in multi-axis machine tool

This paper presents the observation results of realtime milling tool behavior in a g-axis Machining Center and its simulation results of cutting force. There are two gap sensors placed near a tool without contact to detect the tool displacement and a tool dynamometer to detect the cutting force. A hall-nosed end-milling tool is used and climb cutting of oblique plane is done as experiments. Through the observation of tool behavior, two movements of undercutting and recession per tool revolution are found and the measured amplitude of tool displacement; shows a good coincidence with the machining error. Simulation results of cutting force showed the same movement of undercutting and recession but its amplitude is different from that of the measured cutting force.