Optimal deformation error compensation process in flank milling of thin-walled workpieces

In order to reduce static deformation and improve machining accuracy, deformation error compensation by offline adjustment of machining parameters is a practical approach in the flank milling process of thin-walled workpieces. Since machining parameters are coupled with cutting force and deformation, iterative methods are required for error compensation. However, current error compensation models lack an in-depth understanding of the compensation process, resulting in low convergence rate of the compensation process. To overcome these problems, a double flexible error compensation model (DFCM) for deformation is proposed in this paper. As the basis of the proposed model, iterations of machining parameters in error compensation are first introduced. After that, the deficiencies of the flexible error compensation model (FCM) for deformation are revealed, and the reasons for its large iteration space and low convergence rate are given. Then, the DFCM is developed from the flexible iteration process of machining parameters and the FCM. The proposed DFCM reveals the actual error compensation process and has significant advantages over the FCM; thus, it converges with the faster rate. Finally, effectiveness and advantages of the DFCM are verified by simulations and experiments of flank milling of thin-walled workpieces.