Modeling and experimental validation for surface error caused by axial cutting force in end-milling process

The high-speed milling is now the primary machining method of the thin-walled structures. Study on the surface error caused by part deflection has been comparatively mature, yet the deformation mode of the workpiece remains incomplete. This paper studies the milling error caused by the axial cutting force. On the basis of deflection function of the rectangular cantilever plate, a method is proposed to predict the deflection and surface error of the thin-walled part. There is an interplay of cutting force and surface error after machining. As the work suggests, workpiece will be warping under the axial cutting force. And the deformation increased with the increase of cutting depth and the decrease of the spindle speed.