Research on High-Efficiency Milling Process and Machining Parameter Optimization of Aircraft Wing Rib Components

Aircraft rib components, which serve as critical elements within wing structures, present significant challenges in efficient machining due to their intricate geometries, thin-walled low-rigidity characteristics, and high material removal demands. These factors have a direct influence on aircraft development timelines. This study addresses the issues of process instability, limited machining efficiency, and scalability constraints in CNC manufacturing. A systematic framework is proposed that integrates optimized process planning, milling stability analysis, and machining parameter optimization. A vacuum-embedded clamping system secured with hexagonal screws is developed to improve structural stability during operations. A standardized two-stage, four-step machining strategy is established to streamline tooling configurations, toolpath planning, and cutting parameter selection, thereby supporting batch manufacturing. Milling stability is assessed through calibration of cutting force coefficients and single-factor experimentation, while hammer-impact testing is employed to extract frequency response functions for the tool and workpiece. Stable machining regions are identified using a regenerative chatter model and semi-discrete method, with results represented through stability lobe diagrams. A parameter optimization model is formulated to maximize productivity by adjusting spindle speeds, axial and radial depths of cut, and feed rates within system-defined constraints. CNC simulation is employed to refine toolpaths, and experimental validation indicates that rough machining material removal rates increase by over 50%. The primary contributions of this study include: (1) implementation of a unified clamping mechanism and standardized machining protocol to improve repeatability; (2) deformation mitigation through residual stress redistribution and optimized toolpath planning; and (3) stability-based parameter optimization that effectively balances productivity and machining precision. This integrated approach offers a scalable and high-efficiency solution for the manufacturing of rib components, significantly decreasing production cycles while maintaining high standards of quality in aerospace applications.