An analysis on the numerical prediction of surface error in the face milling process of complex structural components

Face milling process simulation and an error prediction approach are studied. A modified cutting force model is put forward and verified through cutting experiments. A thermo-mechanical finite element model is built up to simulate the complex structural component surface machining process, based on machining process analysis, cutting area discretization, and dynamic cutting loads calculation. Simulated machined surface error is predicted and compared with cutting experiment measurement results, the feasibility and validity of the proposed prediction approach is verified.