Case Study: Eliminating Chatter on Aluminum Enclosure

案例：消除铝合金外壳的铣削颤纹

Background (背景)

During the CNC milling of a thin-walled aluminum enclosure, severe chatter marks were observed on the side walls.

在铝合金薄壁外壳的 CNC 铣削过程中，侧壁出现了严重的颤纹。

Root Cause Analysis (根本原因分析)

1. Tool Stick-out (刀具悬伸): The end mill stick-out was 45mm, too long for a 6mm diameter tool.
   • 铣刀悬伸长达 45mm，对于直径 6mm 的刀具来说太长了。
2. Fixture Rigidity (治具刚性): The clamping force was insufficient in the center area.
   • 治具中心区域的夹紧力不足。

Solution (解决方案)

1. Optimized Toolpath (优化刀路): Used a "trochoidal milling" strategy to reduce cutting forces.
   • 采用“摆线铣”策略以降低切削力。
2. Fixture Improvement (治具改进): Added a support block in the center.
   • 在中心增加了支撑块。

Result (结果)

Chatter marks eliminated. Surface finish improved from Ra 1.6 to Ra 0.4.

颤纹消除。表面粗糙度从 Ra 1.6 提升至 Ra 0.4。