Dynamic modeling for the prediction of surface errors in the milling of thin-walled sections

In this paper, computer simulation techniques capable of predicting, off-line, the resulting geometric errors in the finish end-milling of thin-walled sections are presented. The effects of workpiece and cutter dynamic deflections on the chip load are included in the model. The workpiece dynamics are modeled using the finite-element technique. In addition, a technique for the tracking of the changing workpiece geometry during machining is developed so as to enable the changes in the dynamic stiffness of the workpiece to be included in the prediction model.Finally, the effects of process variable such as the immersion ratio, the axial depth of cut, etc. on the resulting surface errors are evaluated using the model developed. The results of the computer simulations are validated experimentally.