Force-induced deformation mechanism for cylindrical shell thin-walled parts milling with ice supporting: Modelling and Prediction

Abstract

Improving the rigidity of the process system in the cutting region of thin-walled parts is a challenging problem to ensure machining accuracy. For limited structural space, the use of ice support is an effective method. However, ice and workpiece constitute a completely new process system, which generates a complex process response under milling forces. Based on the Kirchhoff-Love thin-wall small-deformation assumption and the Winkler model for describing the inverse support of ice on cylindrical shell thin-walled parts (CSTWP), a new prediction model is developed to predict the deflection of CSTWP under ice support. In the model, by introducing the displacement function in the form of annular triangular series, the analytical solution of the displacement is given for the cylindrical shell with non-simply supported edges at both ends under ice support. A finite element model for milling CSTWP under ice support is developed, which takes into account the nonlinear behavior of ice and the complex mechanical behavior of the ice/workpiece interface. Based on this finite element model and the corresponding milling experiments, the accuracy and validity of the established model are verified. The work provides a theoretical basis for the prediction of the deformation of CSTWP under ice support.