<p>The spindle speed regulation method (SSRM) and the sinusoidal variable speed method (SVSM) are two widely adopted passive chatter suppression techniques in milling process. In this paper, a comprehensive thickness reduction milling experiment is conducted on typical thin-walled components by integrating the two aforementioned chatter suppression methods. First, by leveraging the enhanced discretization method [J Mech Sci Technol 38:7 3339–3350, 2024], a stability lobe diagram (SLD) prediction model for the milling process is developed, accounting for both constant spindle speed and sinusoidal speed modulation. This model highlights the machining characteristics specific to thin-walled components. The proposed SLD for sinusoidal speed modulation milling is systematically compared with the improved semi-discretization method [Sci China Technol Sci 56: 648–655, 2013] to rigorously validate its accuracy and reliability. Additionally, by comparing the limiting milling depth under various sinusoidal speed modulation parameters, the globally optimal modulation parameters identified through the energy-based analysis method [Int J Pr Eng Man-GT 12:4, 2024] are numerically validated. Next, considering the varying dynamic characteristics of thin-walled components across different processing regions, distinct chatter suppression methods are applied accordingly. Moreover, Machining parameters are determined using the chatter-free milling parameters predicted by the SLD for both constant and sinusoidal variable speed. Finally, the surface morphology and dimensional accuracy of a 2&#xa0;mm thin-walled component are analyzed to validate the effectiveness of the current chatter suppression strategy and the rationality of the process parameters settings.</p>