The micro-machining scale effect makes it challenging to forecast and control the process parameters of the micro-milling process, which makes the micro-flanking-milling of weak-rigidity micro-thin-walled parts prone to deformation. To determine the critical cutting parameters for chip formation in the micro-milling of curved thin-walled parts at the mesoscale, the strain-softening effect of titanium alloy during high-speed milling and the scale effect of mesoscale cutting were comprehensively considered and a finite element prediction model for curved micro-thin-wall micro-milling was established to determine the critical milling parameters for effective material removal. Based on the determined milling parameters, an experimental design of response surface optimization was carried out. Based on the response surface methodology, a data-driven quantitative model with milling process parameters as design variables and deformation amounts as response variables was established to reveal the influence mechanism of multiple milling process parameters on machining accuracy. Based on the process requirements for deformation control in the micro-milling of curved thin-walled structures, dynamic optimization of the milling process parameters was performed using an improved NSGA-III algorithm to obtain non-dominated solutions. A visual ranking and a determination of the unique solution were conducted using the entropy weight–TOPSIS method. Finally, micro-milling validation experiments were carried out using the optimal parameter combination. The optimal solution for the process parameters of the arc-shaped micro-thin-wall micro-milling of titanium alloy established by the institute provides a relevant reference and guidance for mesoscale arc-shaped thin-wall micro-milling.

The prediction of micro milling forces in difficult-to-machine materials such as titanium alloys, which have small dimensions and arc-thin-walled features, has become a major challenge due to the coupling effect of multi-physics fields. This problem has become a key bottleneck in the development of aerospace, space, biomedical and other fields. To address this issue, this study focuses on titanium alloy arc-thin-walled parts and develops a micro milling force prediction model that considers the dual flexible coupling deformation and geometric features of arc-thin-walled parts in the process of micro milling. Firstly, a micro milling force theoretical model is established based on the instantaneous cutter position angle and the actual instantaneous uncut thickness. Secondly, detailed geometric analysis is conducted to calculate the entry and exit angles and instantaneous uncut thickness considering the characteristics of arc micro milling paths. Subsequently, the Euler beam and Timoshenko beam are assumed based on the characteristics of the cutter and workpiece structure, as well as the force situations. The unit stiffness matrix is then solved to calculate the deflection deformation value. An iterative algorithm is used to introduce the coupling deflection deformation into the micro milling force prediction model, thereby improving the instantaneous uncut thickness model. Finally, the micro milling force data is obtained through arc micro milling experiments and the coefficient of micro milling force is identified. The micro milling force is predicted using a theoretical model and its rationality and accuracy is verified through experiments. The proposed model and methodology have practical significance and provide a basis for optimizing micro milling processes and promoting the development of related fields.