本文针对复杂直纹曲面薄壁件的五轴侧铣加工过程，以保证零件加工精度及提高加工效率为目标，系统地提出了一整套基于加工代码修正的变形误差补偿与进给速度优化方法。主要研究内容和成果可以概括如下：提出了准确快速提取五轴侧铣加工过程中瞬时刀具与工件接触区域的点集筛选法。建立了五轴侧铣加工中关键几何参数的求解模型；基于瞬时刀具位置分析，提出了普通立铣刀外表面可能接触范围的求取方法；明确了点集筛选法的具体实施流程及点云密度选取原则。通过仿真算例表明，该方法与实体建模法具有同等计算精度，但在计算效率上具有明显优势。建立了刀具偏心影响下的五轴侧铣加工切削力高精高效预测模型。基于刀齿圆弧轨迹假设，推导了求取微元切削刃切出角和瞬时未变形切屑厚度的解析表达式；提出了基于三次半径多项式函数的立铣刀圆弧段切削力系数辨识方法；利用机械力学求解模型实现了五轴侧铣加工的切削力预测。开展了典型零件的加工实验，结果显示，切削力的最大预测偏差小于10%，证明了模型的有效性。针对复杂直纹曲面薄壁件加工易变形问题，提出了时变切削力作用下的变形误差预测与补偿方法。分别建立了考虑螺旋载荷分布的悬臂梁模型和考虑材料去除效应的有限元模型计算细长刀具和薄壁工件变形；研究了变形量和切削力之间的耦合作用关系，以迭代计算的方式获取平衡状态下的变形误差；基于镜像原理提出了一种双层迭代误差补偿策略。开展了薄壁S试件的加工实验，应用所提出方法，零件最大轮廓误差由0.129mm降低至0.04mm，加工精度得到显著提升。针对复杂直纹曲面薄壁件的加工工艺参数制定过于保守的问题，提出了多约束下的进给速度优化方法。提出了一种临界消除法用于获取工件侧铣加工后的表面轮廓，建立了五轴侧铣加工表面粗糙度预测模型；分别以变形误差、表面粗糙度和机床额定加速度为限制，制定了进给速度优化与调整原则。开展了薄壁S试件的加工实验，结果表明，采用变进给方法加工的零件其加工精度和表面质量均得到有效控制，同时切削时间减少了30.7%，加工效率得到显著提升。

For the five-axis flank milling process of thin-walled parts with complex ruled surfaces, aiming at ensuring the machining accuracy and improving the processing efficiency, a set of methods of deformation error compensation and feed speed optimization based on tool position file correction are systematically proposed. The main research contents and results can be summarized as follows:A point set screening method is proposed to accurately and rapidly extract the contact area between the instantaneous cutter and the workpiece in the five-axis flank milling process. The solution model of key geometric parameters in five-axis flank milling is established. Based on the instantaneous tool position analysis, the method of calculating the possible contact range of the external surface of common end milling cutter is proposed. The specific implementation process of point set selection method and the principle of selecting point cloud density are clarified. The simulation results show that this method has the same accuracy as the solid modeling method, but has obvious advantages in computational efficiency.A high precision and high efficiency prediction model of cutting force in 5-axis flank milling under the influence of tool eccentricity is established. Based on the assumption of arc path of cutter teeth, the analytical expressions for calculating the cutting edge angle and instantaneous undistorted chip thickness are derived. A method for identifying the cutting force coefficients of the arc section of end milling cutter based on cubic radius polynomial function is proposed. The cutting force prediction of five-axis flank milling is realized by means of Mechanical model. The machining experiments of typical parts show that the maximum prediction deviation of cutting force is less than 10%, which proves the validity of the model.Aiming at the problem of easily deformed thin-walled workpiece with complex ruled surface, a method for predicting and compensating the deformation error under time-varying cutting force is proposed. The cantilever beam model considering helical load distribution and the finite element model considering material removal effect are established to calculate the deformation of slender cutter and thin-walled workpiece respectively. The coupling relationship between deformation and cutting force is studied, and the deformation error under equilibrium state is obtained by iterative calculation. A double-layer iterative error compensation strategy is proposed based on the mirror principle. The processing experiments of thin-walled S specimens were carried out. By using the proposed method, the maximum contour error of parts was reduced from 0.129 mm to 0.04 mm, and the processing accuracy was significantly improved.Aiming at the problem of too conservative formulation of processing parameters for thin-walled parts with complex ruled surfaces, a feed speed optimization method under multiple constraints was proposed. A critical elimination method is proposed to obtain the surface profile of the workpiece after flank milling, and a prediction model of surface roughness for five-axis flank milling is established. The optimization and adjustment principles of feed speed are given with the limitations of deformation error, surface roughness and rated acceleration of the machine tool, respectively. The processing experiment of thin-walled S specimen is carried out. The results show that the machining accuracy and surface quality of the parts processed by variable feed method can meet the standard requirements. Meanwhile, the cutting time is reduced by 30.7%, and the processing efficiency is improved significantly.