A force-induced deformation prediction method without iteration considering the instantaneous undeformed chip thickness update for thin-walled part in flank milling

The thin-walled part is extensively applied to the plentiful industries including automotive and aerospace, which inevitably suffer the force-induced deformation during milling due to their low stiffness characteristics. This leads to a reduction in machining accuracy and even results in component damage. To address the issue, a deformation prediction model without iteration considering the IUCT (Instantaneous Undeformed Chip Thickness) update is proposed.

First, based on the stiffness equation, the node division method is applied to tool-workpiece deformation model, in which solution scale is reduced to improve the model efficiency. Then, to establish an iterative model for the actual deformation, the coupling effect among the milling force, radial cutting depth, IUCT and deformation need to be considered into the prediction model. Next, a non-iterative deformation prediction method is proposed, in which the milling force model is reconstructed to obtain the generalized deformation formula of the closed-form solution. Moreover, the impact of the IUCT update on both milling force and deformation is analyzed. Finally, the correctness of the proposed method is verified through flank milling experiments, which shows the average accuracy of deformation can reach 97.5 %. The accuracy and efficiency of the proposed method are verified in different scenarios by comparison with other methods.