Modelling of static surface error in end-milling of thin-walled geometries

摘要

End milling is commonly employed during fabrication of thin-walled components as it can produce complex shapes in a variety of materials with higher accuracy and productivity. The static deflections of thin-walled components under periodically varying cutting forces are inevitable resulting into surface error and violation of tolerances. This paper presents finite element analysis (FEA) based approach to predict static deflections and resultant surface error during machining of thin-walled components. It has been realised that the axial variation of deflection induced surface error can be linked with cutting conditions. The paper conceptualises various shapes of surface error profile based on similarities of axial and radial engagement. The proposed methodology is implemented in the form of computational models and series of machining experiments are conducted to demonstrate efficacy of the proposed approach. The outcomes of the present study will help process planners in devising strategies to control surface error during milling of thin-walled components.