Research on deformation control of thin-walled parts with support force and milling parameters based on mirror milling system

Aiming at the severe machining deformation of aerospace aluminum alloy thin-walled parts during mirror milling, the coupled influence mechanism of support force and milling parameters on workpiece deformation is investigated based on the finite element software ABAQUS. A finite element model of the mirror milling system is established to analyze the variation law of thin-walled part deformation affected by support force as well as its interaction with milling parameters. On this basis, a numerical simulation model for the milling process is constructed, and workpiece deformation data corresponding to the parameter combination with maximum local stiffness of the workpiece are obtained systematically by orthogonal experimental design. Experimental verification demonstrates that the predicted deformation from simulation agrees well with measured experimental data, with the minimum relative error of 4.38% and the maximum relative error of 9.35%. The research indicates that the parameter optimization method combining finite element simulation and intelligent algorithm can effectively suppress the machining deformation of aerospace thin-walled components and improve their forming quality.