Experimental study on micromilling deformation control of micro-thin wall based on the optimal tool path

Abstract

At the mesoscopic scale, the milling deformation of complex components with micro-thin-walled features such as micro-channel cold plates and aerospace honeycomb materials is the main factor affecting their machining accuracy. In order to effectively control the deformation in the process of milling and improve the machining accuracy of micro-thin wall, this paper starts with improving the stiffness in the milling process of micro-thin wall. Firstly, the deformation control method based on the optimal tool path is proposed during milling the micro-thin wall, including the deformation control of micro-thin wall with cantilever boundary in asymmetric step milling and the deformation control of micro-thin wall with complex boundary in piecewise variable feed milling; secondly, a lots of micro-thin-walled milling experiments are carried out with different milling parameters, tool paths and cooling methods; finally, compared with the free milling, the thickness and surface morphology of micro-thin wall after milling under the two control strategies are analyzed to verify the effectiveness of the control strategy and determine the optimal control strategy.