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Experimental study on micromilling deformation control of micro-thin wall based on the optimal tool path

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Abstract

At the mesoscopic scale, the milling deformation of complex components with micro-thin-walled features such as micro-channel cold plates and aerospace honeycomb materials is the main factor affecting their machining accuracy. In order to effectively control the deformation in the process of milling and improve the machining accuracy of micro-thin wall, this paper starts with improving the stiffness in the milling process of micro-thin wall. Firstly, the deformation control method based on the optimal tool path is proposed during milling the micro-thin wall, including the deformation control of micro-thin wall with cantilever boundary in asymmetric step milling and the deformation control of micro-thin wall with complex boundary in piecewise variable feed milling; secondly, a lots of micro-thin-walled milling experiments are carried out with different milling parameters, tool paths and cooling methods; finally, compared with the free milling, the thickness and surface morphology of micro-thin wall after milling under the two control strategies are analyzed to verify the effectiveness of the control strategy and determine the optimal control strategy.

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Acknowledgements

The authors wish to acknowledge the financial support for this research from the Doctoral Research Fund of Shandong Jianzhu University (Grant No. XNBS1809), Natural Science Foundation of Shandong Province (Grant No. ZR2020QE180, ZR2019MEE029), Key Research and Development Project of Shandong Province (Grant No. 2018GGX105008), Fundamental Research Funds for the Central Universities (Grant No. G2020KY0501) and Foundation Research Project of Taicang City (Grant No. TC2020JC10).

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Authors and Affiliations

  1. School of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China

    Jiaming Zhou & Zexing Wang

  2. School of Mechanical and Electronic Engineering, Shandong Jianzhu University, Jinan, 250101, China

    Jie Yi

  3. School of Automotive Engineering, Shandong Jiaotong University, Jinan, 250023, China

    Fengyan Yi & Jinbo Wang

  4. School of Civil Aviation, Northwestern Polytechnical University, Suzhou, 215400, China

    Junfeng Xiang

  5. National New Energy Vehicle Technology Innovation Center, Beijing, 100176, China

    Zexing Wang

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  1. Jiaming Zhou
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  2. Jie Yi
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  3. Fengyan Yi
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  4. Junfeng Xiang
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  5. Zexing Wang
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  6. Jinbo Wang
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Correspondence to Jie Yi or Fengyan Yi.

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Technical Editor Adriano Fagali de Souza.

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Zhou, J., Yi, J., Yi, F. et al. Experimental study on micromilling deformation control of micro-thin wall based on the optimal tool path. J Braz. Soc. Mech. Sci. Eng. 43, 238 (2021). https://doi.org/10.1007/s40430-021-02962-1

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  • DOI: https://doi.org/10.1007/s40430-021-02962-1

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