In this paper, the FEM analysis and the machining of a workpiece using a non-rotational tool are attempted in order to produce a highly accurate surface on a thin wall. Also, the machining accuracy of the thin wall produced by the non-rotational tool is compared with that produced by an end mill. The main results are as follows. (1) FEM models for the tool and workpiece are made and the machining accuracy is predicted based on the deflection analysis using FEM due to the cutting force. (2) The tendency of the shape of machined surface is almost coincident with that of the predicted shape, so the propriety of the method of analysis is verified. (3) Both dimensional and shape error on the inside and outside surfaces of the workpiece produced by the non-rotational tool prove larger than the predicted values. Although the shape error proved a little larger than the predicted value, the target value of 5μm was achieved. (4) It is shown that the dimensional error due to under cutting decreases with the decrease in the radius of the tool edge. And also, on and after the second cutting process, the cutting at the commanded depth of cut was achieved even if the micro depth of cut.

1. [1] H. Iwabe and H. Mitsuboshi, “Infruence of Eccentricity of Helical End Mill on Working Accuracy,” J. of the Japan Society for Precision Engineering, Vol.61, No.6, pp. 834-838, 1995.
2. [2] H. Iwabe and T. Shimadsa, “Establishment of High-Accurate and High-Efficiency Machining Method for Scroll-Shape Workpiece with End Mill (1st Report, Proposal of High-Accurate and High-Efficiency Machining Method Based on Maximum Chip Area and Surface Roughness),” J. of the Japan Society of Mechanical Engineers, Series C, Vol.61, No.583, pp. 1184-1191, 1995.
3. [3] M. Kohya, M. Shimada, H. Suzuki, Y. Takeuchi, and M. Sato, “Development of CAM System for Non-rotating Machining of Curved Surface,” J. of the Japan Society of Mechanical Engineers, Series C, Vol.62, No.600, pp. 3326-3332, 1996.
4. [4] H. Fukuyama, “Study on High Accurate Machining of Thin Wall Cylinder Workpiece by Non Rotational Tool,” Graduate School of Science and Technology, Niigata University Master Thesis, 2005.
5. [5] N. Ikawa, “Diamond Tool and Workpiece (Conditions of Edge Sharpness, Smothness, Strength and Affinity),” Machine Tools ’84 1st Issue (Ultra Precision Machining),” Taigashuppan, pp. 119-127, 1984.
6. [6] N. Nakamura, “Study on High Accurate Machining of Thin Wall Cylinder Workpiece by Non-Rotational Tool (Analysis based on Deflection of Tool and Workpiece using 3D-CAD,” Graduate School of Science and Technology, Niigata University Master Thesis, 2007.
7. [7] H. Iwabe, T. Oseto, and T. Goto, “Improvement of Surface Roughness for End Milling using Cutting Edge with High-Accurate Flank Surface,” J. of the Japan Society of Mechanical Engineers, Series C, Vol.68, No.666, pp. 650-656, 2002.