Abstract: The geometric and spindle errors inevitably affect the quality of the end turning surface. These errors cause resultant positioning errors at the tool tip, which are defined as the difference between the actual and commanded tool tip position. This paper proposes an approach for modeling and simulation of the surface generated in end turning process. The model incorporates the effects of the positioning errors between the tool tip and the part being machined. It provides the possibility to simulate the surface topography for given errors. Based on the proposed model, groups of simulation experiments are conducted to investigate the effects of geometric and spindle errors on the topography of end turning surface. To further analyze the effect of these errors on the surface roughness, a set of simulation experiments have been designed according to the Taguchi method. The simulation results show that the surface roughness of end turning surface is more sensitive to the spindle displacement error compared with other error components. At the end of this paper, a simple method to find the principal error component is proposed.

Key words: Surface quality, Geometric errors, Spindle errors, Homogeneous transformation matrix (HTM), Principal component analysis (PCA), End turning surface

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