Dynamic modeling and in-process parametric compensation for fabricating micro straight thin walls by micromilling

A comprehensive dynamic model is introduced try to further reduce dimensional errors of micromilled micro straight thin walls based on an in-process cutting parameter compensation device. First, a mathematical model is established to predict the dynamic elastic deformation of the thin walls in the micromilling process. Next, the radial deformation and the runout of the cutter are modeled. Then, the comprehensive in-process parametric compensation model and strategy are established. Finally, a real-time in-process cutting force measurement and cutting parameter compensation device is applied to the micromilling system and thin wall fabrication experiments have been conducted. It shows that the comprehensive dimensional error model and iterative compensation method are effective, and the dimension and shape precision of the micro straight thin wall has been obviously improved after the compensation of the radial cutting depth. The average relative errors have been reduced from 6.86% to 1.10%∼1.70%. The in-process compensation method introduced in this study is efficient and convenient as long as compensation strategies are integrated in the controlling unit for a specific micromilling process.