A FULL-FACTOR ANALYTICAL MODEL OF DIMENSIONAL DISTORTION IN SINGLE-TOOL MACHINING SETUPS CONSIDERING TRANSLATIONAL AND ANGULAR DISPLACEMENTS

Abstract

This paper presents a full-factor analytical model for dimensional distortion in single-tool machining setups, taking into account both translational and angular displacements of the technological system subsystems. It is shown that in machining operations involving workpieces with significantly anisotropic dimensions, angular displacements induced by cutting forces can substantially affect the overall machining accuracy. Unlike previously proposed models, which are limited in scope and often inconsistent with the general principles of the mechanics of elastically deformable systems, the developed model is based on a rigorous matrix formulation of compliance characteristics. The model incorporates both translational and rotational compliance matrices, as well as coordinate transformation matrices associated with the point of force application. A generalized expression for dimensional distortion is derived as a combination of translational and angular components, reflecting the full set of six degrees of freedom. The resulting full-factor model provides a unified and physically consistent framework for analyzing machining errors in single-tool setups.mThe proposed model can serve as a theoretical basis for improving accuracy prediction, technological process design, and further development of computer-aided manufacturing systems.

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