Dynamic Modeling and Stability Prediction in Milling Process of Thin-Walled Workpiece with Multiple Structural Modes

摘要

Regenerative chatter can easily occur in the milling process of thin-walled workpiece due to the inherent low stiffness. This paper aims to predict the milling stability for the milling process of thin-walled workpiece with a complete dynamic model. First, multiple structural modes of thin-walled workpiece are taken into consideration, and a complete dynamic model of thin-walled workpiece milling system is developed. Then, a numerical integration method is extended to achieve the stability lobe diagrams of the milling system and identify the chatter frequency. Besides, the major structural mode, which is responsible for the occurrence of the thin-walled workpiece chatter in the milling process, is predicted. Finally, a series of milling tests concerning a general cantilever plate are conducted, and the test results agree well with the predicted results, which shows the effectiveness of the proposed method.