Modeling of Side Milling Cutting Force on Thin-walled Components Considering Time-varying Effect of Force-induced Deformation

doi:10.3901/JME.260434

Abstract

Abstract: Aluminum alloy thin-walled parts have important applications in the aerospace field due to their light weight and high overall rigidity. Due to the thin thickness of the side wall and web of thin-walled parts, the milling force during machining is a key factor inducing machining errors. In order to further reveal the milling mechanism of thin-walled parts and optimize the cutting process, it is particularly important to accurately predict the cutting force. Aiming at the weak stiffness characteristics of thin-walled parts, a flexible milling force prediction model considering the force-deformation effect is proposed, and the coupling law between milling force and deflection deformation is revealed. According to the Kirchhoff theory and the change of cutter-workpiece contact area caused by workpiece deformation in the milling process, a model of flexible milling force prediction and a finite element calculation method of deflection bending deformation of thin-walled parts are established, which characterize the time-varying contact relationship between the force and the workpiece contact area. The dynamic deformation values generated during the cutting process are used to iteratively correct the instantaneous cutting thickness and improve the prediction accuracy of the milling force model. Comparing the prediction results with the experimental results, the maximum error of the predicted deformation value of the proposed method is within 0.012 mm, and the average error of the milling force prediction in the X and Y directions is less than 10 %, which verifies the accuracy and effectiveness of the model. The established cutting force model can provide a theoretical basis for the reasonable optimization of tool structure and the recommendation of process parameters.

Key words: thin-walled parts, milling force modeling, machining deformation, Kirchhoff theory, finite element calculation

CLC Number:

TH161

XIA Wei, LIU Xianli, YUE Caixu, GUO Yandong, SUN Shaocong. Modeling of Side Milling Cutting Force on Thin-walled Components Considering Time-varying Effect of Force-induced Deformation[J]. Journal of Mechanical Engineering, 2026, 62(9): 430-446.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260434

http://www.cjmenet.com.cn/EN/Y2026/V62/I9/430

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