Stability of micro-milling thin-walled part process

Micro-scale thin-walled parts have the characteristics of small size and low rigidity, so chatter is very easy to occur in high speed micro-milling, which influences machining precision and surface quality of the parts. To solve this problem, the authors first establish micro-milling force models in micro-milling thin-walled parts that consider the elastic deflection of both thin-walled part and micro-milling tool. According to the Lagrange’s equation, the dynamic characteristics of thin-walled part that vary with the cutting position of the tool are obtained combined with the Rayleigh-Ritz method. The relative transfer function between the micro-milling tool and the thin-walled part is achieved through the relationship between cutting force and vibration vector and then the dynamic characteristics of the system are obtained. Finally, the stability lobe diagram is drawn through time-domain simulation and verified by micro-milling experiments. The comparison results show that the prediction results of the stability lobe diagram are consistent with the experimental results. The research is a meaningful exploration of the mechanism of micro-milling thin-walled parts and provides a basis for the selection of cutting parameters for stable cutting.