At mesoscale, dynamic alternating milling forces and relative stiffness of thin wall are the main factors affecting the deformation of thin-walled structures. To improve the machining accuracy and effectively control the thin wall deformation, this paper investigates the control strategies of dynamic milling forces and deformation mechanism in milling of different thin-walled structures. The instantaneous deformation of thin wall in high temperature casting wax supported milling is analyzed. A deformation control method of thin wall based on the dynamic stability of micro milling forces is proposed in high-speed milling process. Three representative milling experiments on microchannel cold plate with cantilevered boundary, single impeller blade with mixed boundaries, and cantilevered structure shaped like variable curvature wavy line are presented. The milling deformation mechanisms of these three thin-walled structures with different target thickness are further investigated in free milling and casting wax supported milling. Compared with free milling, the milling forces and thickness dimension of thin wall machined under different control strategies are analyzed. By monitoring the milling forces in milling of different micro-walled structures, the small difference and fluctuation of milling forces at different positions, together with the reduced thickness errors verify the effectiveness of the control strategies, using high temperature precision casting wax as auxiliary support in reducing the thin wall deflection. Additionally, the optimal milling control strategy of thin wall is determined.

在中尺度上，动态交替铣削力和薄壁的相对刚度是影响薄壁结构变形的主要因素。为了提高加工精度并有效地控制薄壁变形，本文研究了不同薄壁结构铣削中动态铣削力和变形机理的控制策略。分析了高温铸造蜡支撑铣削过程中薄壁的瞬时变形。提出了一种基于微铣削力动态稳定性的薄壁变形控制方法。提出了在具有悬臂边界的微通道冷板，具有混合边界的单叶轮叶片和形状类似变曲率波浪线的悬臂结构上的三个代表性铣削实验。在自由铣削和铸造蜡支撑铣削中，进一步研究了这三种具有不同目标厚度的薄壁结构的铣削变形机理。与自由铣削相比，分析了在不同控制策略下加工的薄壁铣削力和厚度尺寸。通过监视不同微壁结构铣削中的铣削力，不同位置铣削力的细微差异和波动以及减小的厚度误差验证了控制策略的有效性，该工艺使用高温精密铸造蜡作为辅助支撑。减少薄壁挠度。另外，确定了薄壁的最佳铣削控制策略。