An effective methodology for predicting the stability of thin-walled components during milling process

The present study proposes an effective operational procedure to address the issue of chatter prediction in milling thin-walled components. Firstly, the milling force coefficients are determined using an iterative cyclic structure based on the calibrated values of the average force method, resulting in a closer alignment between the identified values and the measured ones. Then, the prediction of time-varying dynamic parameters of thin-walled parts, which represents the most critical and intricate challenge in chatter prediction of thin-walled components, is accomplished by using the fixed component modal synthesis (CMS) method and dead element technique. The accuracy of the prediction results is validated through impact hammer tests. Subsequently, a stability lobe diagram (SLD) based on the discretization method is presented, considering the influence of multi-point contact but representing it by a single point contact model. This approach demonstrates exceptional computational efficiency while maintaining calculation accuracy. Finally, the aforementioned solutions are comprehensively implemented to accurately predict the stability of thin-walled components. The milling experiments are specifically designed for typical thin-walled components, the findings demonstrate accurate prediction of chatter phenomenon and the chatter free region is expanded by spindle speed selection method.