The thin-walled parts have the characteristics of low stiffness and time-varying dynamics in the milling process, and the vibration in the milling system plays a major role in surface topography generation. In this paper, a novel surface topography prediction model is developed considering cutting vibration and material removal effect for the peripheral milling of thin-walled parts with curved surfaces. Compared with the traditional surface topography generation model, the relative tool-workpiece vibration, material removal effect and workpiece surface geometry are considered simultaneously. The time-varying dynamic modal parameters of the thin-walled part are estimated through the structural dynamic modification method. Then the influences of cutting vibration and material removal effect are investigated. The milling experimental results indicate that the proposed model can predict the surface topography and roughness parameters accurately under the machining condition of large axial cutting depth, which can also perform well at a slight chatter state. The material removal effect and system vibration jointly contribute a great deal to surface topography generation.

薄壁零件在铣削过程中具有低刚度和时变动力学的特点，铣削系统中的振动在表面形貌的生成中起主要作用。在本文中，针对具有曲面的薄壁零件的周边铣削，开发了一种新的表面形貌预测模型，该模型考虑了切削振动和材料去除效应。与传统的表面形貌生成模型相比，同时考虑了刀具-工件的相对振动、材料去除效果和工件表面几何形状。通过结构动力学修正方法估计薄壁零件的时变动态模态参数。然后研究了切削振动和材料去除效果的影响。铣削实验结果表明，该模型能够在大轴向切削深度的加工条件下准确预测表面形貌和粗糙度参数，在轻微颤振状态下也能表现良好。材料去除效应和系统振动共同对表面形貌的产生有很大贡献。