High-Order Exponentially Fitted Methods for Accurate Prediction of Milling Stability.

IF 3 3区 工程技术 Q2 CHEMISTRY, ANALYTICAL
Micromachines Pub Date : 2025-08-29 DOI:10.3390/mi16090997
Yi Wu, Bin Deng, Qinghua Zhao, Tuo Ye, Anmin Liu, Wenbo Jiang
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引用次数: 0

Abstract

Regenerative chatter is an unfavorable phenomenon that severely affects machining efficiency and surface finish in milling operations. The prediction of chatter stability is an important way to obtain the stable cutting zone. Based on implicit multistep schemes, this paper presents the third-order and fourth-order implicit exponentially fitted methods (3rd IEM and 4th IEM) for milling stability prediction. To begin with, the delay differential equations (DDEs) with time-periodic coefficients are employed to describe the milling dynamics models, and the principal period of the coefficient matrix is firstly decomposed into two different subintervals according to the cutting state. Subsequently, the fourth-step and fifth-step implicit exponential fitting schemes are applied to more accurately estimate the state term. Two benchmark milling models are utilized to illustrate the effectiveness and advantages of the high-order implicit exponentially fitted methods by making comparisons with the three typical existing methods. Under different radial immersion conditions, the numerical results demonstrate that the 3rd IEM and the 4th IEM exhibit both faster convergence rates and higher prediction accuracy than the other three existing prediction methods, without much loss of computational efficiency. Finally, in order to verify the feasibility of the 3rd IEM and the 4th IEM, a series of experimental verifications are conducted using a computer numerical control machining center. It is clearly visible that the stability boundaries predicted by the 3rd IEM and the 4th IEM are mostly consistent with the cutting test results, which indicates that the proposed high-order exponentially fitted methods achieve significantly better prediction performance for actual milling processes.

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铣削稳定性精确预测的高阶指数拟合方法。
在铣削加工中,再生颤振是一种严重影响加工效率和表面光洁度的不利现象。颤振稳定性预测是获得稳定切削区的重要途径。基于隐式多步格式,提出了铣削稳定性预测的三阶和四阶隐式指数拟合方法(三阶和四阶)。首先,采用具有时间周期系数的时滞微分方程(DDEs)描述铣削动力学模型,并根据切削状态将系数矩阵的主周期分解为两个不同的子区间;随后,采用第四步和第五步隐式指数拟合方案更准确地估计状态项。利用两个基准铣削模型,通过与现有三种典型方法的比较,说明了高阶隐式指数拟合方法的有效性和优越性。在不同的径向浸没条件下,数值结果表明,与其他三种现有的预测方法相比,第3种和第4种方法具有更快的收敛速度和更高的预测精度,且计算效率损失不大。最后,利用计算机数控加工中心进行了一系列的实验验证,以验证第三次和第四次IEM的可行性。可以清楚地看到,第3次和第4次IEM预测的稳定性边界与切削试验结果基本一致,这表明所提出的高阶指数拟合方法对实际铣削过程的预测效果明显更好。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Micromachines
Micromachines NANOSCIENCE & NANOTECHNOLOGY-INSTRUMENTS & INSTRUMENTATION
CiteScore
5.20
自引率
14.70%
发文量
1862
审稿时长
16.31 days
期刊介绍: Micromachines (ISSN 2072-666X) is an international, peer-reviewed open access journal which provides an advanced forum for studies related to micro-scaled machines and micromachinery. It publishes reviews, regular research papers and short communications. Our aim is to encourage scientists to publish their experimental and theoretical results in as much detail as possible. There is no restriction on the length of the papers. The full experimental details must be provided so that the results can be reproduced.
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