An advanced FEA based force induced error compensation strategy in milling

The study introduces a multi-level machining error compensation approach focused on force-induced errors in machining of thin-wall structures. The prediction algorithm takes into account the deflection of the part in different points of the tool path. The machining conditions are modified at each step when the cutting force and deflection achieve a local equilibrium. The machining errors are predicted using a theoretical flexible force-deflection model. The error compensation is based on optimising the tool path taking into account the predicted milling error. The error compensation scheme is simulated using NC simulation package and is experimentally verified.