A special deformation prediction model for titanium alloy in thin wall machining is established and calibrated by micromilling experiments. The model has been successfully evaluated by micromilling experiments. It shows that the dimensional errors of the thin wall made of Ti-6Al-4V are significantly reduced after on-machine radial cutting depth compensations. The relative errors have been reduced from 16.5 % to 3.9 %.

This investigation is a further study on the consideration of the cutting edge radius of the cutter and the material of the workpiece based on the methods of finite element simulation and the micro end cutting experiment. The minimum undeformed chip thickness (MUCT) value increases with the increase of the cutting edge radius, no matter which process. In this study, the influence of important variables on MUCT is studied as much as possible to reflect a real application situation.