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The vibration in milling process plays a key role in machining, which will significantly affect the machining quality of workpiece. Some vibrations have negative influences on the workpiece surface, while particular vibrations are able to improve machining stability. Therefore, it is critical to distinguish the influence of different types of vibration on the machining quality. A simulation method of undeformed chip thickness considering process vibration is presented in this article, in which a finite element model is established to analyze the dynamic milling process of 7075-T651 aluminum alloy from the aspects of cutting force and temperature. A series of experiments are carried out to verify the effectiveness of the simulation model, and the results show that the proposed model is accurate in predicting milling force and temperature. Furthermore, the effect of milling vibration on machining performance is studied with the proposed method, in which the relationship between amplitude-frequency characteristics of vibration and milling forcetemperature fluctuation is revealed. The results show that the proposed method can define the influence of milling vibration and provide a basis for distinguishing favorable and unfavorable vibration parameters of machining quality in milling.

A good understanding of the dynamic characteristic in milling of aerospace aluminum, especially the coupling vibration caused by the interaction of the manufacturing process and the machine tool, helps promote the machining precision and surface quality of aerospace structural components. This paper is devoted to proposing the interaction theory of the vibration and dynamic force, which is verified in the milling of Al 7075-T651 by consideration both the machine tool load and machining process dynamic load. First, through detailed analysis of the interaction effect of vibration and the dynamic force, the dynamic milling process is simplified to theoretically model the dynamic interaction in the precision manufacturing process under non-chatter condition. Then, the dynamic process force, which is the key source of the interaction, is modeled and obtained based on wavelet packet transform preprocess; the Frequency Response Function (FRF) of machine tool is regarded as the interaction link between the dynamic force load and the vibration response; the machine tool non-cutting vibration is transformed as a special dynamic load superposed on the response. Finally, the interaction vibration is calculated applying interaction effect model, the predicated results obtained in interaction effect approach match well with the vibration signal directly obtained in the test.

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