A numerical approach for the prediction of static surface errors in the peripheral milling of thin-walled structures

Simulation based error compensation strategies offer great potential for the milling of thin-walled structures, which is a key process in, for example, the production of structural aerospace components. However, in many industrial applications, complex numerical models or compensation strategies that result in increased machining times, prevent them from being used for process design in a profitable manner. In this article, a numerical approach for the prediction of static surface errors in the peripheral milling of thin-walled structures based on tool and process parameters is presented. The proposed model is designed for the usage within a previously introduced framework that aims towards making virtual compensation strategies more attractive for industrial applications. It is experimentally validated by comparing predicted error profiles with the optically measured finishing surface of thin-walled aluminum plates that were machined with varying process parameters. By using the presented numerical model, the surface error can be accurately predicted, even for small radial cutting depths where the presence of tool runout significantly affects the generation of the surface.