Compensation of tool deflection based on drive currents

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Tool deflection, caused by process forces, severely affects machining accuracy in milling processes. This transfer project extends and transfers the methods and knowledge on compensation of tool deflection, which were developed in the project N1. The project is conducted in collaboration with DECKEL MAHO Seebach GmbH. The goal is to increase machining accuracy by up to 80%. To achieve this, process forces are estimated from drive currents and deflection is calculated synchronously to the interpolation cycle of the machine tool control. The adaptive control strategies from project N1 are applied to minimize the resulting path deviation. In order to ensure industrial practicability, autonomous identification routines and heuristics for process specific parametrization are developed as well. Finally, the system is validated in technical and economic terms in close collaboration with the transfer partner.