Current Research and Equipment Evolution in Mirror Milling for Large Thin-walled Components

doi:10.3901/JME.260398

Abstract

Abstract: With escalating demands for machining precision and efficiency of large thin-walled aerospace components, mirror milling achieves breakthroughs in process system rigidity and adaptability through its “simultaneous milling-supporting, thickness preservation and vibration suppression” methodology, retaining the advantages of the low mechanical stress in chemical milling and program controllability in CNC single-machine milling. Its key technologies include: (1) mirror synchronization accuracy assurance technology, enhancing absolute pose accuracy through kinematic modelling and error compensation, coupled with mirror toolpath optimization and coordinated motion control to ensure dynamic tracking accuracy; (2) conformal support and thickness assurance technology, enabling adaptive conformity to part contours and precise thickness regulation via support structure design, force/position control and thickness compensation; (3) mirror machining chatter suppression technology, mitigating chatter risks by integrating machining dynamics modelling with passive vibration suppression (offline optimization of stiffness/damping) and active vibration suppression (dynamic adjustment of stiffness/damping) strategies. Configuration innovation emerges as the pivotal pathway for system enhancement and application advancement, promising to overcome quality/efficiency bottlenecks in machining aircraft skins and rocket tank domes. Furthermore, mirror milling’s continuous evolution promises broad prospects, with its large-scale application in thin-walled component manufacturing proving vital to national aerospace high-end manufacturing development.

Key words: mirror milling, synchronous control, flexible support, chatter suppression, configuration innovation

CLC Number:

TG156

XU Chenhao, XIE Fugui, XIE Zenghui, LIU Xinjun. Current Research and Equipment Evolution in Mirror Milling for Large Thin-walled Components[J]. Journal of Mechanical Engineering, 2026, 62(13): 349-362.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260398

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