Control of the Milling Mode of a Thin-Walled Console Plate by Indirect Indicators

The article presents a theoretical study of the change in the deflection of a thin rectangular plate depending on the position of the point of application of force simulating the load from the cutter. The modeling was carried out for two typical processing trajectories  along the length and along the width of the plate. The deflections and the corresponding stiffness values are calculated, the dependencies are obtained and their features are interpreted. It is found that the adopted algorithm of the calculation is similar to the calculation algorithms used in existing CAE systems. Based on this, it is proposed to use the data, in particular the plate deflection value, as an indirect indicator for controlling the milling mode. The indirect indicators adopted as the initial ones are approximated as a power polynomial with a certain approximation reliability R2. It is proposed to use the obtained polynomials to create the corresponding inversely proportional polynomials that determine one of the main indicators of the milling mode  the linear feed of the spindle. The software implementation of the proposed solution was carried out using an extended G-code, which suggests the use of the proposed solution for a wide range of CNC milling machines. Practical testing of the obtained software solutions was carried out, confirming their full operability. The research results allow increasing the stability of the milling process when processing low-rigid cantilever-fixed parts on machines without an active control system, including active feedback “part  tool  machine”. This approach allows using cheaper machines while obtaining acceptable quality of machined surfaces, which, in turn, determines a decrease in the cost of manufactured products and increases production efficiency.