Review of milling chatter in aerospace thin-walled structures

The machining of thin-walled structures in aerospace manufacturing is frequently constrained by chatter, which significantly impairs dimensional accuracy, surface integrity, and tool life. This study provides a comprehensive review of the dynamic characteristics, prediction methodologies, and suppression strategies for milling chatter in thin-walled aerospace components. Techniques for characterizing the dynamic behavior of milling systems, including the tool, spindle, and workpiece, are examined, encompassing impact testing, frequency response function measurement, and finite element analysis. Chatter prediction approaches are reviewed, ranging from empirical and analytical models to finite element simulations and advanced intelligent prediction methods. Chatter suppression strategies are discussed across passive, semi-active, and active control technologies, highlighting their respective applicability and performance. Particular emphasis is placed on recent progress in digital twin technology, enabling real-time process monitoring and the integration of predictive control for chatter mitigation. A theoretical framework for chatter prediction and control in the context of digital twin assisted machining is presented. The review concludes with an outlook on future developments, emphasizing the need for high-fidelity multi-physics computational models, adaptive control algorithms, and full integration of digital twin technology to achieve more efficient, precise, and reliable machining of thin-walled structures.