Tool deflection investigation and deflection compensation of drill thread milling

This paper investigates tool deflection and its compensation in Drill Thread Milling (DTM), a novel method for internal thread fabrication. The study proposes a heuristic model that integrates lateral force estimation and soft collision techniques to counteract tool deflection. The model’s effectiveness was validated through extensive experiments across various cutting conditions, workpiece materials, and thread sizes. Results indicate that feed per tooth significantly affects tool deflection more than cutting speed, and low machinability materials exhibit greater deflection. Larger thread sizes also lead to increased deflection due to higher cutting forces. The proposed compensation method effectively reduces deflection, ensuring the resulting threads meet specified standards. This study provides valuable insights for optimizing DTM processes, improving precision, and enhancing manufacturing efficiency.