Where, in the CAD, CAM, controller workflow, is it appropriate to model and compensate for how the cutting tool path will deviate from the desired path under the applied cutting forces?
The loop through the machine (from where the work and tool meet through the work, work holding, table, axis slop, machine base, spindle, and back to where the tool meets the work) should have a measurable stress/strain curve. Theoretically, this could be be used to alter how the tool moves when cutting.
Maybe the controller reads load-cells in the machine, references a stress/strain table, and steps accordingly?
Maybe the CAM app can generate dynamic feed and speed or change the shape of the tool bit or something?
Maybe a CAD operation changes the shape of the model before feeding it to CAM?
I’m new to machining and I assume this is an old problem with well developed solutions in a specific field with specific key-words. Please let me know if you have any recommendations on:
I’m not aware of similar settings at least in standard machines, the most usual way is to use data and lower the step and feed, leaving an allowance slightly larger paths) and make a finish pass with appropriate steps and feed to finish the part in term of dimensions and machine marks.
I doubt that apart from dedicated program there is CAM software (that should do a FEM or similar analysis of the whole machine and used tools) that could automatically compensate for these flexings and playing.
CAM or software will never help you with this problem. Newer machines have probing systems or just probes that can make offsets based on program parameters and using variable programming to cut the part again but that is about it. There are many factors that come into play here. Work holding is a big one. Flat parts may need a vaccum plate / chuck to keep the part flat on the table while machining because a vise may cause flex in the flat plate. Long tooling with small diameters may flex and the cutting strategy may need to be fine tuned. Then there is the speeds and feeds that can cause issues. This is as much of a science as it is an art or craft. This is a good question and asking it now will save you hours of searching for an answer. The answer lies in your machining strategy. Now you know to spend your time on the solution and finding a process that works for the particulars you are dealing with.
These should open up an excellent can of worms and keep me busy for a few years.
It looks like most of the work is in the controller, but there may be some spillover in CAM. I will have to spend some time digging in open-source controller projects to see what has already been accomplished.