Numerical Modeling and Experimental Validation of Machining of Low-Rigidity Thin-Wall Parts

In the present work, a realistic three-dimensional thermomechanical finite element method (FEM) based model is developed to simulate the complex physical interaction of helical cutting tool and workpiece during thin-wall milling of an aerospace grade aluminum alloy. Lagrangian formulation with explicit solution scheme is employed to simulate the interaction between helical milling cutter and the workpiece. The behavior of the material at high strain, strain rate, and the temperature is defined by Johnson–Cook material constitutive model. Johnson–Cook damage law and friction law are used to account for chip separation and contact interaction. Experiments are carried out to validate the results predicted by the developed 3-D numerical model. Four case studies are conducted to test the capability of developed 3-D numerical model. It is noted that the milling force and wall deformation predicted by the developed model match well with the experimental results. Overall, this work provides a useful tool for prior study of the precision machining of low-rigidity thin-wall parts.