Surface topography prediction in peripheral milling of thin-walled parts considering cutting vibration and material removal effect

The thin-walled parts have the characteristics of low stiffness and time-varying dynamics in the milling process, and the vibration in the milling system plays a major role in surface topography generation. In this paper, a novel surface topography prediction model is developed considering cutting vibration and material removal effect for the peripheral milling of thin-walled parts with curved surfaces. Compared with the traditional surface topography generation model, the relative tool-workpiece vibration, material removal effect and workpiece surface geometry are considered simultaneously. The time-varying dynamic modal parameters of the thin-walled part are estimated through the structural dynamic modification method. Then the influences of cutting vibration and material removal effect are investigated. The milling experimental results indicate that the proposed model can predict the surface topography and roughness parameters accurately under the machining condition of large axial cutting depth, which can also perform well at a slight chatter state. The material removal effect and system vibration jointly contribute a great deal to surface topography generation.