Study On Thin-walled Part Deformation And Error Compensation In Milling Process

In aeronautic/aerospace field, more and more key functional parts or components with sculptured surfaces use thin-walled parts. However, the characteristics of thin-walled parts such as integrity, large area, low-rigidity, hard-machining etc. determined that the precision of them are difficulty to be controlled. How to predict deformation error and compensate it in milling process is a challenge for researchers and manufactures. Based on successful research findings of literatures, this paper analyzes the properties of the milling process and does some works as follows:Firstly, cutting force model for end mill. Based on orthogonal milling process, analyzing the relationships between cutting forces and parameters of materials and the angles of the cutter, the cutting forces on every cutting element using orthogonal/inclined relationship are computed, finally, the total cutting forces impacted on the cutter are obtained, and the key parameters of the cutting force model, instantaneous uncut chip thickness, is computed in this paper.Secondly, analyzing the temperature field and stress field, and the finite element model is set up adopting direct-coupling method, the using the iterative method, the deformation error curves are predicted and finally the deformation error surface is obtained through interpolation method.Then, utilizing three and five-axis compensation method, the deformation surface is compensated.Finally, using AL7075-T6, a series of experiments are executed, the results shows that there are consistent with each other, between experiment data and simulation data, further more, both three and five-axis compensation method can deduce the deformation error, but five-axis compensation method is of more precision and takes full advantage of five-axis machine center.