Error Compensation Strategies for Workpiece Deflection During End Milling of Thin-Walled Straight and Curved Geometries

Abstract

Thin-walled parts and their precision manufacturing is finding importance in the field of aerospace as well as automobile component manufacturing industries. The value of machining of thin walls like honeycomb structures increases because of the efficiency of such parts in any assembly as robust members which results in reducing the fuel usage and increasing strength of the system. In this part of research work, characterization of surface errors and compensation of errors by offline toolpath modification techniques is discussed. Major concerns of machining in end milling and cutting conditions variables include axial as well as radial depths of cut. After validation of errors by some results of cutting experiments toward predicted using a model, compensation strategies negating the errors are proposed. The results are directly applicable to similar manufacturing of various complex parts.