Abstract
This paper proposes a new efficient iterative algorithm which named flexible iterative algorithm (FIAL) with a general approach suitable for surface form errors prediction in peripheral milling of thin-walled workpiece. First, a FEA-Based model is presented to analyze the surface dimensional errors in peripheral milling of thin-walled workpieces. Then the FIAL is discussed in detail for the procedure of deformation prediction. From FIAL, an iterative scheme for the calculations of tool/workpiece deflections considering the former convergence cutting position are developed，in the scheme a small variable must be included in the calculation of radial cutting depth which never been considered in the literatures before.The proposed approach is validated and proved to be efficient through comparing the obtained numerical results with the test results.
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