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Related Experiment Video

Updated: Feb 3, 2026

Immunostaining of Biocytin-filled and Processed Sections for Neurochemical Markers
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Thin-Walled Double Side Freeform Component Milling Process with Paraffin Filling Method.

Jun Zha1, Jing Chu2, Yipeng Li3

  • 1State Key Laboratory for Manufacturing Systems Engineering, Xi'an Jiaotong University, Xi'an 710000, China. jun_zha@xjtu.edu.cn.

Micromachines
|November 8, 2018
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Summary

This study introduces a paraffin filling method to improve the precision of milling thin-walled, double-sided freeform components. The filling technique significantly enhances accuracy, reducing surface errors in complex part manufacturing.

Keywords:
filling methodfreeform surfacethin-walled double side

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • Machining thin-walled, double-sided freeform components presents significant challenges due to geometric complexity, high accuracy demands, and low structural stiffness.
  • Existing milling processes often struggle to achieve the required precision for these intricate parts.

Purpose of the Study:

  • To investigate and evaluate the effectiveness of a filling method during the milling of thin-walled, double-sided freeform components.
  • To enhance the geometrical accuracy and surface quality of manufactured components.

Main Methods:

  • Utilized DEFORM-3D for surface residual stress analysis to inform rough milling parameter selection.
  • Employed the Taguchi method to optimize rough milling parameters, validated by experimental residual stress measurements (within 15% difference from simulation).
  • Determined semi-finishing and finishing parameters using the equal error step length and step distance method.
  • Conducted comparative machining experiments with and without paraffin filling, measuring accuracy with a coordinate measurement machine.

Main Results:

  • Without filling, achieved peak-to-valley (PV) values of 25.16 μm (concave) and 20.34 μm (convex), with root-mean-square (RMS) values of 13.75 μm and 11.93 μm, respectively.
  • With the paraffin filling method, PV values improved to 8.53 μm (concave) and 7.12 μm (convex), and RMS values improved to 2.45 μm and 3.05 μm.
  • Simulation results for residual stress showed less than 15% difference compared to experimental data.

Conclusions:

  • The paraffin filling method significantly improves the machining accuracy of thin-walled, double-sided freeform components.
  • This technique offers a viable solution for overcoming stiffness limitations and achieving high-precision manufacturing of complex geometries.
  • Optimized milling parameters, informed by simulation and experimental validation, are crucial for successful implementation.