Based on the stability lobe diagram of two degrees of freedom milling system obtained by using the numerical method, two kinds of cutting conditions (stable and unstable) are selected to perform the cutting tests of aeronautical monolithic components. Cutting distortion and secular distortion are measured and analyzed by using the MISTRAL 775 coordinate measuring machine (CMM), respectively. Influences of chatter on machining distortion are investigated. It is shown that, both machining distortion and secular distortion are smaller in stable case; in unstable case, machining distortion is also smaller, while secular distortion is very large, and torsion occurs in the workpiece end with larger box. Therefore, workpiece need be machined in stable conditions for subsequent assembly work, especially aeronautical monolithic components.

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