Chatter Suppression in the Milling Process of Thin-walled Components with Continuous Sinusoidal Spindle Speed Variation

Thin-walled components have garnered significant attention due to their time-varying dynamic characteristics and susceptibility to chatter. Continuous sinusoidal spindle speed variation (CSSSV) emerges as a prominent method for chatter suppression. In this paper, the CSSSV is integrated with spindle speed selection method (SSSM) to effectively suppress chatter during the finishing stage of thin-walled components. In contrast to continuous cutting operations such as turning, milling is characterized by an interrupted machining process, particularly during the finishing stage of thin-walled components. According to the inherent structural characteristics of typical thin-walled components, the impact of tool positions and material removal on workpiece dynamics is taken into consideration. Therefore, distinct chatter suppression methods are employed in different processing regions. The CSSSV process involves two crucial parameters that exert a significant influence on the stability of machining process: the CSSSV amplitude ratio and signal frequency. The impact of the aforementioned two parameters on the stability of continuous and interrupted machining under high and low spindle speed conditions is compared and analyzed through an energy-based analysis. The optimal CSSSV parameters are determined through numerical simulation in order to minimize the work done by the regenerative force, thereby achieving a more stable milling state. Finally, synchronous motion programming is employed to achieve the CSSSV machining on a five-axis machining center, and experimental validation is conducted.