Dimensional surface error prediction model in five-axis flank milling for thin-walled parts

For five-axis flank machining process, the static deflection of cutter and workpiece creates surface errors that leads to disqualification in thin-walled parts industry. In order to concentrate on mentioned issues, the dimensional surface error is predicted in the paper which is caused by cutting force. First, the cutter is processed for a cantilever structure, hence the analytical solution for deformation of end-mill can be obtained. Then, the flexible cutting force is distributed on finite element (FE) model of workpiece. The stiffness of the workpiece varies with the material removal. Subsequently, a flexible iterative calculation method for deflection prediction is achieved. Finally, the presented model is demonstrated by machining a thin-walled parts, in which the surface error prediction coincides with the experimental results.