A Simplified Analytical Model for Strip Buckling in the Pressure-Assisted Milling Process.

A simplified column-buckling model is developed to understand the buckling mechanism of thin-walled strips restrained by uniform lateral pressure in the milling process. The strip is simplified as two rigid columns connected by a rotation spring, resting on a smooth surface, restrained by a uniform pressure and loaded by an axial force. Two loading cases are considered, i.e., the dead load and the follower load. Analytical solutions for the post-buckling responses of the two cases are derived based on the energy method. The minimum buckling force, Maxwell force and stability conditions for the two cases are established. It is demonstrated that the application of higher uniform pressure increases the minimum buckling force for the column and thus makes the column less likely to buckle. For the same pressure level, the dead load is found to be more effective than the follower load in suppressing the buckling of the system. The effect of initial geometric imperfection is also investigated, and the imperfection amplitude and critical restraining pressure that prevent buckling are found to be linearly related. The analytical results are validated by finite element simulations. This analytical model reveals the buckling mechanism of strips under lateral pressure restraint, which cannot be explained by the conventional bifurcation buckling theory, and provides a theoretical foundation for buckling-prevention strategies during the milling process of thin-walled strips, plates and shells commonly encountered in aerospace or automotive industries.