FEM-Based Simulation for Workpiece Deformation in Thin-Wall Milling

Abstract

This paper focuses on the deformation of a thin wall during the milling process. Cutting experiments were performed to investigate the influence of the workpiece thickness on its deformation and the cutting force. An FEM-based model was developed to simulate the deformation of a thin-wall workpiece during the milling process. With a tool’s rotation, the cutting force is distributed along the helical cutting edge, and the workpiece deformation can be calculated for a given time interval. The simulated results were compared with those of a simpler model where a constant cutting force is uniformly distributed along an oblique line representing the material removal by a cylindrical tool. Finally, the application of these results to the design of ribs for thin-wall parts during machining was considered.