Prediction of machined part accuracy from machining system capability

A novel methodology for linking machining system capability to the accuracy of a machined part is presented. Using special testing equipment, force-deviation functions in the real machine workspace are obtained. An elastically linked multi-body simulation and FE model evaluates the volumetric deviations. The deviation values are then calculated for a particular tool path. The forces and the deviations along the tool path are computed and compared with results obtained from machining experiments. This approach yields elimination of laborious machining experiments and supports an unequivocal control of machining system conditions giving the required level of part accuracy.