To fulfill the lightweight requirements of helicopter transmission systems

transmission gears as a critical component of helicopters

possess the noticeable characteristic of thin walls

which presents challenges in terms of severe deformation and the assurance of dimensional precision during the machining process. This article focuses on the study of thin-walled gear spoke plate made from high-strength medium alloy carburized steel. Using the ABAQUS finite element analysis software

a simulation study on the cutting process was conducted. By establishing a three-dimensional dynamic cutting simulation model

the relationship between the cutting forces and the cutting parameters on the parts in the machining was analyzed. Static simulation methods were used to analyze the influence of the superposition of cutting force and clamping force on the processing deformation of thin-walled spoke. Then range analysis was used to examine the simulation results. Finally

the experimental validation of the simulation results was carried out. The results indicate that in the static analysis of gear thin-walled spoke plate machining deformation

the axial deformation of the gear spoke plate is most significant

and the radial deformation is most prominent at the hub. Range analysis reveals that the optimal cutting parameters are the cutting speed of 150 m/min

the feed rate of 0.06 mm/r

and the cutting depth of 1.8 mm

with the prediction error for the maximum deformation of below 10%.