Process Stabilization through Cryogenically Generated Support Structures and its Impact on Dimensional Accuracy in Milling Thin-Walled Components

When milling thin-walled components, their low rigidity often leads to undesirable dynamic effects such as chatter. Cryogenically generated support structures, formed by expanding liquid CO₂ and injecting a coolant-lubricant emulsion, create a temporary ice layer that stiffens and damps the workpiece during machining. While previous studies included analogy tests and initial milling experiments with one process configuration, a broader and systematic evaluation has not yet been carried out. This study conducts systematic milling experiments to directly evaluate the influence of cryogenic ice layers on process dynamics, examining how they can enhance stability while also introducing challenges such as thermal contraction and component distortion. In addition to process stability, the study analyzes component contour deviations as a measure of thermally induced distortion, while surface quality is evaluated as a direct indicator of dynamic instabilities. The results provide new insights into the interaction between cryogenic support structures and thermally induced effects, advancing the understanding of their potential in stabilizing thin-walled component milling.