Three-dimensional process stability prediction of thin-walled workpiece in milling operation

High-speed machining of thin-walled workpiece is widely used in aerospace industry. To optimize the machining parameters in milling operations, the related process stability is required to be predicted. Compared to the existing two-dimensional (2D) milling stability model, a more completed three-dimensional (3D) regenerative process stability prediction model of thin-walled workpiece is presented based on the newly developed dynamic model. The efficiency and accuracy of the regenerative milling stability can be improved in the presented 3D model. The analysis procedure of the stability of flexible dynamic milling is developed in details. The 3D stability lobes are calculated according to the full discretization method and direct integration scheme. To verify the accuracy of presented 3D stability model, the thin-walled workpiece milling sound pressure signal and surface quality are determined in experiments.