The Application of an Optical Measurement System to Investigate Strains in a Thin-Walled Element During Milling

The paper presents a methodological innovation, i.e. the application of the Aramis system to measure the deformation of thin-walled element during the milling process. An important problem related to the milling of a thin-walled part is the occurrence of springback, a phenomenon which causes a significant post-machining deformation of this part, primarily in the form of a distinctive trapezoidal cross section of the wall. The study involved conducting a finishing milling operation for aerospace aluminum alloy 7050 T7451. A Zeiss advanced optical measurement system Aramis Adjustable $\mathbf{1 2 M}$ along with the Zeiss Inspect Correlate software were used. Results demonstrated that the workpiece underwent noticeable deformation as a result of tool load. Particularly noticeable was the displacement of the upper part of the wall, where the maximum deflection was observed when the tool was distanced by $L=20 \mathrm{~mm}$ from the face of the wall. It was found that the application of the optical measurement system to investigate the milling process of thin-walled parts and their deformation posed a number of challenges. The dynamic nature of the machining process and rapidly changing phenomena in the machining zone made it difficult to capture displacements with high accuracy. A suitable experimental setup was also required.