Adaptive tool path generation for flank milling of thin-walled parts based on force-induced deformation constraints

The thin-walled workpiece is affected by the weak rigidity of the workpiece which will lead to force-induced deformation during the five-axis flank milling. To solve this problem, this paper explores the relationship between cutting force and deformation after establishing the cutting force model. Firstly, the error function under single tool position is established to optimize the tool axis vector, so that the tool can close to the ruled surface, and then tool position is extracted to represent the tool posture in the five-axis flank milling process. Based on the geometric model, a calculation model of cutter-workpiece engagement (CWE) is described by combining the discrete geometry method and the analytical method. And the problem of calculating the instantaneous chip undeformed thickness (ICUT) is transformed into the intersection problem of cylinder surface from cutting point to previous tooths; the model is used to simulate the five-axis milling process and predict the cutting force. On the basis of the above work, the force-induced deformation model of tool and workpiece is established to compensate the deviation by adjusting the tool point and tool axis vector. The effectiveness of force model is verified by cutting force experiments. After that, the machining experiments were carried out by the optimized tool paths, and the measurement results show that the optimized machining error is obviously improved.