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This paper, on the basis of error modelling, proved the optimal pocket machining sequences of a simply end supported pocketed beam using mathematic induction method. The optimal pocket machining sequence with the minimum pocket floor height error is the machining from both ends to the middle and the optimal sequence is not unique because of the symmetric supports about the central plane; meanwhile, the optimal pocket machining sequence with the minimum wall position error is the machining from the fixed end to the free end and the optimal machining sequence is unique. A beam of Al7075 (744 mm in length, 172 mm in width, and 100 in thickness ) with 9 pockets was used to demonstrate the optimal sequences. One of the optimal sequence with minimum floor height error was used in pocketing (roughing), and the maximum distortion was 0.693 mm in the middle and the maximum floor height error appeared on both sides rather than the middle, which were 0.477 mm and 0.388 mm, and part growth produced maximum wall position error was 0.719 mm. On the same part, further demonstrated the optimal sequence with minimum wall position error in finishing (with 1 mm dimension in stock for all surfaces) and the wall position errors were fully removed. The pocketed beam machining is a typical and representative case and the results and conclusion can be extended to pocketed plate/board machining and even surfacing.

Error modelling–based machining sequence optimization of a pocketed beam milling: part A, end supported beam