A point-based variation propagation model for multi-pass machining process

In a machining process, the workpiece is usually machined by several passes to achieve the desired dimension and form. Workpiece deviation generated in the previous pass will affect the next pass. A new point-based variation propagation model for a single machining process with multi-passes was proposed in this article to investigate the relationships between different passes. The effects of locating errors, geometric errors of machine tool, and tool deflection on workpiece deviation are analyzed. Based on these analyses, a point-based variation propagation model for a machining process with multi-passes was derived. By including the influence of the tool deflection, a linkage between workpiece deviation and the cutting parameters is established. Since different passes are distinguished by their cutting parameters, the relationships between different passes are built up via this model. At the end of this article, case studies were carried out to validate the model and its application in cutting parameters’ optimization.