Research on the milling stability of thin-walled parts based on the semi-discretization method of improved Runge-Kutta method

Chatter is a very common phenomenon in the milling process. The occurrence of chatter will cause chatter marks on the processed surface, cause the tool to jump, and even bring sharp and harsh noise, making the processed surface unable to meet the accuracy requirements. Thin-walled parts are more prone to chatter due to their lower stiffness. In order to avoid the occurrence of chatter, this paper adopts the method of combining theoretical analysis with milling experiments to conduct in-depth research on the prediction of chatter. Considering the first-order and second-order modal parameters of the tool and thin-walled part as well as the specific processing parameters, based on the milling dynamics model, a semi-discretization method based on the improved Runge-Kutta method (IRKM-SDM) is used to draw the chatter stability lobe diagram. Through simulation and experiments, it is proved that in terms of simulation accuracy and calculation speed, compared with the zero-order analysis (ZOA), multi-frequency solution (MFS), and the traditional semi-discretization method (SDM), the stability lobe diagram obtained by the IRKM-SDM is more advantageous. This study is of great significance for optimizing cutting parameters and suppressing chatter in the actual machining process.