变形是难加工材料薄壁零件切削加工所面临的最主要挑战之一，整个工艺过程，零件残余应力随材料去除不断演化，导致最终零件的精度很难保证。针对薄壁零件切削加工变形问题，提出一种考虑工艺过程残余应力演化的薄壁零件变形控制方法。首先，通过微元切片法建立了薄壁零件工艺过程简化模型，分析了零件夹紧点的载荷分布，建立了零件夹紧点等效载荷平衡方程；并基于变形叠加原理和微小变形理论，建立了零件夹紧点变形几何平衡方程；分析了工艺过程不同时刻的零件载荷分布情况，揭示了薄壁零件残余应力及其等效载荷演化机理。在此基础上，建立了工序间零件变形精确调控模型，实现了薄壁零件残余应力演化与最终变形控制。最后，设计了3组切削加工实验，分别采用不同加工工艺加工相同的薄板零件，实验结果表明，采用所提出的变形控制方法最大可降低加工变形82.2%。

Deformation is one of the most important challenges in the machining of the thin-walled component， especially for the complicated thin-walled component with difficult-to-machining material. The internal stress and machining induced residual stress are evolved during the machining process， causing the poor machining accuracy of the final component. To solve this problem， a deformation control method based on the evolution mechanism of residual stress is proposed. Firstly， the simplified model of the component is obtained through the slice method. The equilibrium equation for clamping point is established by analyzing the loads distribution. The geometric equilibrium equation is then obtained according to the deformation superposition principle and micro deformation theory. The distribution of loads at different instants of machining process is analyzed， and the evolution mechanism of the residual stresses and the equivalent loads is revealed. Secondly， a mathematical model is established to regulate the in-process deformation of the thin-walled component. As the result， the evolution of the residual stresses and the deformation of the final component is controlled. Finally， 3 deformation validation experiments are carried out to process the same thin plates， and the deformation of the thin plates are compared. The experimental results indicate that the maximum deformation can be reduced by 82.2%.