Numerical prediction of static form errors in peripheral milling of thin-walled workpieces with irregular meshes

The finite element formulation is studied in this paper to predict static form errors in the peripheral milling of complex thin-walled workpieces. Key issues such as cutter modeling, finite element discretization of cutting forces, tool-workpiece coupling and variation of the workpiece's rigidity in milling are investigated. To be able to predict static form errors on the machined surface of complex form, considerable improvements are made on the proper modeling of the material removal in milling and the iterative calculations of tool-workpiece deflections. A general simulation approach is developed based on 3D irregular finite element meshes. By using illustrative examples, rigid and flexible models are compared with existing ones to show the validity of the approach.