Deformation prediction and error compensation in multilayer milling processes for thin-walled parts

Deformation prediction and error compensation are effective approaches to improve machining accuracy in milling thin-walled parts. In this paper, it is considered that the machining deformation of the previous layer will influence the nominal cutting depth of the current layer. Therefore, a dynamical model is established to predict the deformation in multilayer machining a thin-walled part. The coupling relation between cutting force and machining deformation is taken into account using iterative computation. The dynamical model is validated by comparing the simulation result with the experimental one. A new approach of active error compensation is proposed, in which the machining error is compensated at each layer. By comparing the simulation results of compensation at the last layer with the results of compensation at per-layer, a conclusion is drawn that compensation at per-layer makes smaller machining errors and the errors are more uniform. (C) 2009 Elsevier Ltd. All rights reserved.