Abstract: In the end milling process, the elements which influence generation of milled surfaces include milling force/torque, machine tools’ and workpieces’ characters, and so on. Through studying these elements, based on the relationship between milling force/torque and instantaneous underformed chip thickness, an analytical model for end milling surface error with considering cutting force/torque was buit to predict the surface geometrical error in the end milling conditions. Compared with the numerical model, the analytical model is more propitious to studying relationship between process parameters and surface geometrical error. It is also useful to identify the relationship between process parameters and workpieces’ quality, product designing, process planning and controlling. It is a useful aid for the analytical of end milling process design and optimization. A serial of cutting experiments were performed to verify the ability of the models to predict surface geometrical error. Through simulation test, some useful conclusions were drawn.

Key words: Milling force, Milling modeling, Milling torque, Surface error, Dynamic availability of the house, Interval Grey Relational Analysis, Self-correlation, Machining Center