Abstract Dynamic characteristics of thin-walled parts milling system have position-dependent and aggregation modes, which means that multi-modes are close with each other. They (generally the first few vibration modes) may be simultaneously excited by cutting forces in milling process. Therefore, multi-modal couple effect plays a significant impact on thin-walled parts milling process in some cases. The existing Single Mode Theory (SMT) cannot accurately predict milling stability. Additionally, it is very difficult for traditional experimental modal analysis method (e.g., hammer test) to extract the dynamic characteristics of structures in order to handle the coupling modes. To overcome these problems, Multi-Modes Theory (MMT) is updated and investigated thoroughly, and a comprehensive method, Modal Coupled Method (MCM) is proposed to consider these effects in the paper, where the thin plate theory and penalty parameter method are employed and integrated to model the system structure and boundary conditions. Then the comparisons with MCM and existing multi-modes method - Lowest Envelope Method (LEM) and SMT are presented and discussed to confirm the efficiency and accuracy of this method applied to stability prediction of thin-walled parts milling. Finally, two case studies are performed to verify the consistency between the numerical and experimental results, it’s show that for the system with time-varying dynamic characteristics, e.g., thin-walled part milling process, MCM is the better choice for stability prediction when the modal coupling characteristics are unknown, because to determine whether the modes are coupled or not at different cutting positions ahead of time is very difficult.

中文翻译：

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多模态耦合作用下薄壁构件铣削动力学模型及稳定性预测

摘要 薄壁零件铣削系统的动力学特性具有位置依赖和聚集模式，这意味着多模式相互接近。它们（通常是前几个振动模式）可能在铣削过程中被切削力同时激发。因此，在某些情况下，多模态耦合效应对薄壁零件的铣削加工产生重大影响。现有的单模态理论 (SMT) 无法准确预测铣削稳定性。此外，传统的实验模态分析方法（如锤击试验）很难提取结构的动力特性以处理耦合模态。为了克服这些问题，对多模式理论 (MMT) 进行了彻底更新和研究，并采用了一种综合方法，论文中提出了模态耦合方法（MCM）来考虑这些影响，其中采用并集成薄板理论和惩罚参数方法来对系统结构和边界条件进行建模。然后介绍并讨论了与 MCM 和现有多模式方法 - 最低包络法 (LEM) 和 SMT 的比较，以确认该方法应用于薄壁零件铣削稳定性预测的效率和准确性。最后，通过两个案例研究验证了数值和实验结果的一致性，表明对于具有时变动态特性的系统，例如薄壁零件铣削过程，MCM 是稳定性预测的更好选择，当模态耦合特性未知，