Deformation prediction in flank milling of thin-walled parts based on cutter-workpiece engagement

Due to the weak rigidity of thin-walled parts, deformation inevitably occurs due to the influence of cutting forces during the machining process, making it challenging to achieve high machining accuracy. To address the above problem, it is necessary to conduct advanced predictions to determine the machining errors in thin-walled parts. This paper proposes a force-induced deformation prediction model based on cutter-workpiece engagement (CWE). The thin-walled structure is divided into two substructures, removal volume and workpiece. The finite element (FE) model of removal volume between any two discrete feed positions can be constructed based on CWE. At each feed position, the birth-death element method is employed to simulate actual material removal, updating the workpiece's stiffness. In the simulation process, utilizing node offset techniques to modify the cutter-workpiece contact zone, ensuring a high level of geometric consistency between the workpiece's FE model and its actual machining shape. Finally, the proposed method is proven via flank milling experiments. The machining errors predicted using the method proposed in this paper exhibit higher accuracy.