Prediction of form error during face turning on flexible Inconel 718 workpiece

Complex workpieces may contain thin sections that are more likely to deform during machining due to cutting forces. It may result in form errors on the final product. Then, it is important to anticipate such defects when programing tool paths. A mechanist formulation of the cutting forces model, considering tool wear, is proposed in association with a part flexibility model to determine elastic deformation during face turning of thin Inconel 718 discs. A specific experimental methodology has been developed to validate the simulation results by performing in-situ measurements of form error.