Stability Prediction of Multi-Factor Coupled Cast Iron Milling System Based on an Improved Full-Discretization Method.
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| Title: | Stability Prediction of Multi-Factor Coupled Cast Iron Milling System Based on an Improved Full-Discretization Method. |
|---|---|
| Authors: | Zhang, Han1 (AUTHOR) zhanghan@sdjzu.edu.cn, Li, Minghui2 (AUTHOR), Xia, Yan3,4 (AUTHOR) |
| Source: | Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2658. 28p. |
| Subjects: | Discretization methods, Interpolation, Milling machinery, Damping (Mechanics), Vibration (Mechanics), Stability theory, Iron founding |
| Abstract: | Cast iron components are indispensable in aerospace and automotive systems, yet their milling operations are severely affected by regenerative chatter, which degrades machining quality and damages equipment. Although various chatter prediction methods have been reported, the optimal interpolation strategy of full-discretization methods (FDMs) for multi-factor coupled dynamic systems remains unclear. This study proposes an enhanced FDM to fill this research gap. A dynamic milling model accounting for regenerative effects, modal coupling and process damping is established, and an improved FDM based on Lagrange interpolation is further developed. A systematic single-factor analysis is carried out to examine the performance of 1st–4th-order interpolation for state, delay and periodic terms. Counter-intuitively, convergence analysis and stability lobe diagram (SLD) verification reveal that higher-order interpolation does not guarantee better performance. The optimal orders are identified as 2nd/3rd for state terms, 3rd for delay terms and 1st for periodic terms. Accordingly, the proposed 321-FDM (3rd-order state, 2nd-order delay, 1st-order periodic) exhibits higher accuracy and computational efficiency compared with benchmark methods, namely the semi-discretization method and Hermite-based 3rd-order FDM. Milling experiments on cast iron workpieces validate the established model and the 321-FDM, and the experimental stability thresholds agree well with numerical predictions. This work presents a validated, high-performance stability prediction tool for chatter avoidance in cast iron machining. [ABSTRACT FROM AUTHOR] |
| Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
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| Header | DbId: egs DbLabel: Engineering Source An: 194907732 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Stability Prediction of Multi-Factor Coupled Cast Iron Milling System Based on an Improved Full-Discretization Method. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Zhang%2C+Han%22">Zhang, Han</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> zhanghan@sdjzu.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Li%2C+Minghui%22">Li, Minghui</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Xia%2C+Yan%22">Xia, Yan</searchLink><relatesTo>3,4</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2658. 28p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Discretization+methods%22">Discretization methods</searchLink><br /><searchLink fieldCode="DE" term="%22Interpolation%22">Interpolation</searchLink><br /><searchLink fieldCode="DE" term="%22Milling+machinery%22">Milling machinery</searchLink><br /><searchLink fieldCode="DE" term="%22Damping+%28Mechanics%29%22">Damping (Mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Vibration+%28Mechanics%29%22">Vibration (Mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Stability+theory%22">Stability theory</searchLink><br /><searchLink fieldCode="DE" term="%22Iron+founding%22">Iron founding</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Cast iron components are indispensable in aerospace and automotive systems, yet their milling operations are severely affected by regenerative chatter, which degrades machining quality and damages equipment. Although various chatter prediction methods have been reported, the optimal interpolation strategy of full-discretization methods (FDMs) for multi-factor coupled dynamic systems remains unclear. This study proposes an enhanced FDM to fill this research gap. A dynamic milling model accounting for regenerative effects, modal coupling and process damping is established, and an improved FDM based on Lagrange interpolation is further developed. A systematic single-factor analysis is carried out to examine the performance of 1st–4th-order interpolation for state, delay and periodic terms. Counter-intuitively, convergence analysis and stability lobe diagram (SLD) verification reveal that higher-order interpolation does not guarantee better performance. The optimal orders are identified as 2nd/3rd for state terms, 3rd for delay terms and 1st for periodic terms. Accordingly, the proposed 321-FDM (3rd-order state, 2nd-order delay, 1st-order periodic) exhibits higher accuracy and computational efficiency compared with benchmark methods, namely the semi-discretization method and Hermite-based 3rd-order FDM. Milling experiments on cast iron workpieces validate the established model and the 321-FDM, and the experimental stability thresholds agree well with numerical predictions. This work presents a validated, high-performance stability prediction tool for chatter avoidance in cast iron machining. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.3390/ma19122658 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 28 StartPage: 2658 Subjects: – SubjectFull: Discretization methods Type: general – SubjectFull: Interpolation Type: general – SubjectFull: Milling machinery Type: general – SubjectFull: Damping (Mechanics) Type: general – SubjectFull: Vibration (Mechanics) Type: general – SubjectFull: Stability theory Type: general – SubjectFull: Iron founding Type: general Titles: – TitleFull: Stability Prediction of Multi-Factor Coupled Cast Iron Milling System Based on an Improved Full-Discretization Method. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Zhang, Han – PersonEntity: Name: NameFull: Li, Minghui – PersonEntity: Name: NameFull: Xia, Yan IsPartOfRelationships: – BibEntity: Dates: – D: 15 M: 06 Text: Jun2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 19961944 Numbering: – Type: volume Value: 19 – Type: issue Value: 12 Titles: – TitleFull: Materials (1996-1944) Type: main |
| ResultId | 1 |
