Chatter stability in robotic milling of low-rigidity components considering machining deformation and forced vibration coupling

Robotic milling of low-rigidity components constitutes a dually flexible system where stability is critically affected by the complex dynamics at the tool-workpiece interface. A comprehensive multi-point contact dynamics model that integrating machining deformation and forced vibration coupling is established, including their influence on process damping. A stability prediction method based on the multi-point contact dynamics model is developed and experimentally validated. The results indicate that incorporating deformation and vibration effects significantly enhances the accuracy of stability predictions. The stability region exhibits an overall expansion after accounting for machining deformation and forced vibration coupling effects. Specifically, the stability boundary improvement domain reaches a maximum of 40% compared to traditional models that neglect these coupled dynamic effects in several narrow spindle ranges. This work provides a theoretical framework for high-stability robotic milling by identifying the previously neglected role of coupled interface dynamics.