Dynamic modeling of thin-walled CFRP surface milling and the effect of chatter on surface quality

Milling a thin-walled curved structure is prone to chattering and cannot guarantee the quality of the machined surface. Studies of milling thin-walled curved structures on metallic parts have been investigated for years, while in terms of carbon fiber-reinforced plastic (CFRP) parts with a strong anisotropic nature, the tool-material cutting interactions would change at any positions and directions, resulting in a significant change in dynamic cutting force and more complex chatter. Thus, further dynamic modeling should be modified to predict machining chattering accurately. This study introduced the anisotropic and laminated features of CFRP into the machining dynamic model and stability domain solution prediction in milling CFRP. A dynamic cutting force model under the regenerating mechanism was first proposed by considering the instantaneous fiber cutting angle and the cutting edge length of the immediate contact micro-element with the same fiber layer. Moreover, the dynamic model for milling this CFRP workpiece was established based on the dynamic cutting force model and dynamic characteristics of the workpiece. The stability lobe diagram was drawn, and the stable cutting regions were obtained for milling CFRP. Also, experimental verifications were conducted, and the chattering and steady machining conditions were well predicted. Compared with the stable area obtained without considering the anisotropic characteristic of CFRP, the expected maximum peak value of the stable region increased by 49.7