Experimental investigation and modeling of thermal and mechanical influences on shape deviations in machining structural parts

The paper describes an experimental investigation of the surface error generation in machining of thin-walled structural parts. The influences of process induced temperatures and deflections were experimentally investigated for a peripheral milling process with an endmill. The resulting surface error is discussed in consideration of the thermal and mechanical influences on surface generation. A FE-simulation is used to separate the influence of thermal deviations from process-force induced deflections. Finally, a process model is presented, which is able to predict the generation of shape deviations based on the workpiece deflections measured. The simulation result will be compared to the surface measured and the surface error is separated into main shape dominances affected by thermal and mechanical loads.