Compensation of deformation errors in five-axis flank milling of thin-walled parts via tool path optimization

In flank milling of thin-walled parts, the profile tolerance would usually be violated by the excessive static deformations. This paper presents a comprehensive method to compensate deformation errors in five-axis flank milling from the aspect of tool path optimization. Firstly, the machined surface is constructed by imprinting the predicted tool/workpiece deformations on the cutter envelope surface. Secondly, the signed distances from the sample points on the design surface to the machined surface are calculated for the machining error evaluation. Their differential increments that characterize the variation of surface errors with respect to the adjustment of tool path are then derived. On this basis, the mathematical model and algorithm for minimizing the deformation-induced surface errors are developed through slightly optimizing the shape parameters of the tool path surface. Finally, five-axis blade milling experiments are conducted to validate the effectiveness of the proposed method. The results demonstrate that the surface errors mainly caused by machining deformations in flank milling of flexible blades can be largely reduced by using the developed algorithm.