Modeling and simulation of big deformations of thin walled plate in end milling process

With the development of the modern aircraft, the large-scale thin walled parts have been used in aeronautics and astronautics. In NC milling process, the thin walled plates are very easy to deform which will influence the accuracy and quality. From the point of view of theoretically and numerical calculation, the paper proposes a new analytical deformation model suitable for static machining error prediction of low-rigidity components. The part deformation is predicted using a theoretical big deformation equations model, which is established on the basis of the equations of Von Karman when the linear load acts on thin-wall plates. The part big deformation is simulated using FE analysis. The simulating results shown that the diverse cutting forces, milling location and thickness of the plate may lead to various deformation results.