Helical milling is a newly developed hole-making technology in aircraft assembly. The radial cutting force generated in the process of helical milling causes deflection deformation of the tool, resulting in hole diameter deviation. To overcome this problem, the hole diameter deviation test of helical milling is performed on titanium alloy, and the effect of different processing parameters including feed direction on hole diameter deviation is analyzed. Based on the kinematic principle of helical milling, the material removal mechanism and the radial cutting force direction are studied, and variation rules and the formation reasons of hole diameter deviation are analyzed in different feed directions, which is further verified by the cutting force test of helical milling. In addition, the shape of undeformed chip and the change of radial cutting force were examined with different processing parameters, followed by the study of the parameter effect on the change trend of the hole diameter. Results show that the tool is affected by radial cutting force in directions away from the hole center, leading to deflection deformation away from the hole center, and further resulting in hole diameter being larger than the nominal hole diameter in a clockwise feed direction. The opposite is true when the feed direction is counterclockwise. The hole diameter deviation is aggravated with the increase of feed speed and pitch, while weakened with that of the cutting speed.
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