Predictive model for workpiece surface error due to machining processes

The machined surface error is strongly contributed by the external loads and fixturing during machining processes. An integrated model of the entire fixture-workpiece system is developed to investigate the influence of clamping preloads and machining forces on the surface error for machined workpiece. The effects of fixture compliance, workpiece and its locators/clamps contact interaction, and forced vibration, on the machined surface error are also analyzed. The deck face of a V-type engine block subjected to fixture clamping and face milling operation is given as an example. Comparison between the simulation result and experimental data shows a reasonable agreement.