Improving machining performance of thin-walled parts is of great significance in aviation industry, since most aviation parts are characterized by large size, complex shape, and thin-walled structure. Machining process monitoring is the essential premise to improve the machining performance. In order to improve the machining quality and efficiency, this paper presents a position-oriented process monitoring model based on multiple data during milling process, and corresponding solution is provided. Through obtaining the internal data set of the numerical control (NC) system during machining, it is possible to correlate the cutting position with monitoring signals including cutting force, acceleration, and spindle power. Then, process optimization is realized to improve the machining quality and efficiency based on the monitoring results. Machining tests are conducted on aircraft structural part as well as blade part, and the experimental results show this method provides a significant insight into the machining process of thin-walled part and contributes to the process optimization. By using feedrate optimization, time consumption for the rough milling process of one titanium alloy part reduced from 19.1 h to 14.4 h and the number of cutter consumption dropped from 5 to 3. And according to the result of position-oriented process monitoring, the machining strategies were optimized to reduce vibration and avoid chatter, thereby improving the machining quality.

提高薄壁零件的加工性能在航空工业中具有重要意义，因为大多数航空零件具有尺寸大、形状复杂和薄壁结构的特点。加工过程监控是提高加工性能的必要前提。为了提高加工质量和效率，本文提出了一种基于多数据的铣削加工过程监控模型，并给出了相应的解决方案。通过在加工过程中获取数控系统的内部数据集，可以将切削位置与切削力、加速度、主轴功率等监控信号关联起来。然后，根据监测结果实现工艺优化，提高加工质量和效率。对飞机结构件和叶片件进行了加工试验，实验结果表明该方法对薄壁件的加工过程提供了重要的洞察力，有助于工艺优化。通过进给率优化，一个钛合金零件的粗铣加工时间从19.1 h减少到14.4 h，刀具消耗量从5减少到3。优化策略以减少振动和避免颤振，从而提高加工质量。实验结果表明，该方法对薄壁零件的加工过程提供了重要的洞察力，有助于工艺优化。通过进给率优化，一个钛合金零件的粗铣加工时间从19.1 h减少到14.4 h，刀具消耗量从5减少到3。优化策略以减少振动和避免颤振，从而提高加工质量。实验结果表明，该方法对薄壁零件的加工过程提供了重要的洞察力，有助于工艺优化。通过进给率优化，一个钛合金零件的粗铣加工时间从19.1 h减少到14.4 h，刀具消耗量从5减少到3。优化策略以减少振动和避免颤振，从而提高加工质量。