Effect of part-cutter deflection on flexible milling force in high speed peripheral milling process

To improve the problem of dimensional accuracy of the profile for very flexible components during high speed milling process, a new method, to determine the relationship between deflection of low-rigidity process system and milling force, is approached. Based on the application of Bending-torsional coupled theory, a theoretical model to analyze the deflection of thin-walled part is determined, which can more accurately model the specific geometry and structural behaviour of the part-cutter. Taking into account the deflections the immersion angle and chip thickness have been introduced. The milling force distribution is solved iteratively by the modified Newton-Raphson method in this study. From the simulation and experimental results, it is concluded that the milling forces depend on the deflection of thin-walled part. Finally, the flexible force model has been experimentally validated and the results have shown good convergence between predicted and measured force values.