Deflection prediction of micro-milling Inconel 718 thin-walled parts

• Published in: Journal of materials processing technology Vol. 291; p. 117003
• Main Authors: Jia, Zhenyuan, Lu, Xiaohong, Gu, Han, Ruan, Feixiang, Liang, Steven Y.
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.05.2021
• Subjects: ABAQUS; Deflection prediction; Inconel 718; Micro-milling; Thin-walled parts; Micro-milling; Deflection prediction; ABAQUS; Thin-walled parts; Inconel 718
• ISSN: 0924-0136
• DOI: 10.1016/j.jmatprotec.2020.117003

There has been a great increase in the applications of micro thin-walled parts in many fields, such as medical devices, aerospace and so on. The requirement of machining dimensional accuracy for micro thin-walled parts is very high. Inconel 718has the advantages of high strength and corrosion resistance, which can meet the requirements of micro thin-walled parts under poor applying working conditions. However, it is difficult to machine. Micro-milling is a potentially effective processing technique for processing Inconel 718 thin-walled parts. Because of the low rigidity, deflection of Inconel 718 thin-walled parts is easy to occur in micro-milling process, which affects the machining accuracy. So far, the research on the deflection of micro-milling Inconel 718 thin-walled parts is still blank. In this paper, a method of deflection prediction of micro-milling thin-walled parts is proposed. Firstly, a simulation model of micro-milling Inconel 718 thin-walled parts process is established, which realizes the prediction of milling force. Then, by using element birth/death technique, a deflection prediction model of micro-milling thin-walled parts is built based on the predicted value of milling force output by the simulation model, which achieves the more efficient and accurate deflection prediction of micro-milling thin-walled parts. Finally, the correctness of the built simulation model of micro-milling thin-walled parts process as well as the deflection prediction model of micro-milling thin-walled parts are verified by experiments. The research provides a feasible way for deflection prediction of micro-milling thin-walled parts, and lays foundation for deflection suppression and machining accuracy improvement of micro-milling thin-walled parts to a certain extent.