Machining simulation and deformation prediction in the processing for thin-walled parts

Machining simulation and deformation prediction are effective approaches to improve machining error in processing thin-walled parts. However, the empirical studies are still insufficient to improve this problem. This paper uses the finite element method, through cutting process modeling, material removal modeling and calculating the initial residual stresses in machining process to predict and analyze machining-induced deformation. Emphasis is on predicting the effects of cutting parameters on the residual stresses distribution which causes the deformation. Mechanistic model for cutting force estimation, material removal model and prediction model for residual stresses are used in this paper. It is shown that depth of cut and cutting speed play a minor role. On the contrary, the feed rate produces pronounced effects on the residual stresses distribution.