Microturning 61

slides or linear motion guideways. In order to overcome resonance at the operational speed
range of the spindle, proper material selection and design of the machine components are
necessary to have high natural frequency as well as less vibration during the operation of
the machine.

3.4.2 Sources of Errors in Microturning

In microturning, which is a high-precision machining process, the margin of error must be
extremely small. As discussed in the previous section, not only inaccuracies of the machine
tool but also other factors such as the properties of the work material and the reaction
forces against it significantly affect component accuracy. In order to maintain a high level
of precision in microturning, it is important to know the factors responsible for errors dur-
ing the process of generating the shape. Identification of these errors and minimizing their
influence are essential to reach the level of the defined precision. Figure 3.3 shows the major
sources of errors in microturning. The geometrical inaccuracies of the machine tool are
reflected proportionately, whereas positional and repeatability errors are reflected directly
on the component. They affect the size and shape of the component significantly. Similarly,
any deformation caused by mechanical or thermal sources contributes to component error.
Rigidity of the work material becomes a major source of error. Unlike in the micromilling
process, where the cutters have high rigidity and are subjected to less deflection, the rotat-
ing workpiece in microturning is less rigid and undergoes larger deflection during the
material removal process. Components with higher rigidity in terms of material property,
geometry, and L/D ratio are subjected to less deflection and fewer inaccuracies. Similarly,
variation in the grain size and its orientation cause fluctuation in cutting forces and result
in increased inaccuracy of the component.
The magnitude of the reaction force acting on the component is significantly affected
by tool attributes such as cutting edge sharpness (cutting edge radius), tool nose

Machine tool Work material

Mechanical and thermal deformation Rigidity (stiffness)

Geometrical inaccuracies Variation in grain size

Error sources
in microturning

Cutting tool Reaction forces

Material Resultant thrust force on the component

Cutting edge radius, tool nose radius

FIGURE 3.3
Error sources in microturning.