Machining-path mapping from free-state to clamped-statefor thin-walled parts

Thin-walled parts with curved surface are widely used in industrial applications and the high-quality machining is still a major problem because of the low stiffness. By using the machining-path obtained from the design model of thin-walled parts with curved surface, the machining accuracy requirement may easily not be met due to the springback of clamping deformation when the machining process is finished. It is a novel idea that when the machining-path mapping from free-state to clamped-state is realized based on the clamping deformation, the final machining-path of thin-walled parts can be re-designed to directly ensure the machining accuracy requirement after the fixture is released. Based on the concomitant thought of curved surface and the elastic deformation theory of thin shell in this study, the mathematical model for the machining-path mapping from free-state to clamped-state is established for the thin-walled parts with curved surface. Then, the corresponding relationship of cutter contact (CC) points is calculated by grid mapping. Finally, the machining-path for the thin-walled parts with curved surface is re-designed under the clamped-state. Taking a thin-walled cylinder workpiece as an example, the experiment results show that the proposed method can achieve the avoiding purpose for the machining error caused by clamping deformation. These research achievements are of vital importance for realizing high-quality machining of the thin-walled parts with curved surface.