An Advanced FEA Based Analytical Strategy for the Milling of Overall Thin-Walled Workpieces

Abstract

A multi-level finite element analysis approach is introduced to investigate force-induced deformations in milling of overall thin-walled structures. This prediction algorithm takes into account the deformation of the workpiece in different points of the tool path. The machining conditions are modified at each analysis step when the cutting force and deformation achieve a local equilibrium. The effects of feed rates on the workpiece form deformation can be predicted using a theoretical workpiece model. In addition, this methodology can be used to compensate the machining error taking into account the predicted workpiece deformations.