A new localization theory of thin-walled feature machining for near-net-shape part

Localization is usually required for the near-net-shape billet before machining. In conventional research, the to-be-cut features only need to be transformed into the middle of billet to leave the to-be-cut material. However, if it is applied on the thin-walled feature, the machined feature would easily be beyond tolerance due to cutting deformation. Thus, conventional localization principle is not best for the thin-walled feature before the machining. To reduce reject rate for the near-net-shape billet, a new localization theory for the thin-walled features is investigated in this article. The workpiece’s stiffness and cutting force distribution are considered in thin-walled feature localization. By the adjustment of the to-be-cut material, the cutting force is optimized to control the deformation of workpiece. Base on this principle, the cutting deformation is introduced into the constraint conditions of the localization optimization. Thus, the deviation of machined feature is prevented to be outside of tolerance as much as possible. In this work, a practical plate machining is rendered to verify this approach. It lays a theoretical foundation of thin-walled feature localization and is an effective solution for improving qualification rate of the near-net-shape part in industry.