Deflection error modeling during thin-wall machining

The appearance of deflection errors is a common issue during the milling of thin-walled components for the aerospace industry. Their low stiffness generates the need to minimize the cutting forces to avoid deformations, inducing low Material Removal Rate (MRR) and low productivity values. The present paper introduces a finite difference (FD) model coupled to a surface heightmap model for the prediction of forces and deflections generated during milling of thin-walled geometries. The capabilities of the model are evaluated in comparison to experimental tests. Results show that forces and deflections can effectively be predicted, enabling their control while keeping the machining productivity.