International Journal of Machine Tools & Manufacture最新文献

{"title":"Suppression of hot cracking in Ni-based single-crystal superalloys fabricated by laser directed energy deposition through thermal cycle regulation","authors":"Yan Zeng,&nbsp;Boyuan Guan,&nbsp;Tianyu Yuan,&nbsp;Huitao Chen,&nbsp;Lei Li","doi":"10.1016/j.ijmachtools.2025.104283","DOIUrl":"10.1016/j.ijmachtools.2025.104283","url":null,"abstract":"<div><div>The fabrication of Ni-based single-crystal (SX) superalloys through laser directed energy deposition (L-DED) is hindered by the high susceptibility of SX structures to hot cracking. Therefore, achieving crack-free SX superalloys during L-DED is crucial for advancing the application of this technology in SX turbine blade repair. Based on solidification shrinkage and solid-bridging theory, this study systematically investigated the formation mechanisms of hot cracks in a multi-pass multi-layer DD6 SX prepared by L-DED through microstructure characterisation and coupled thermal-mechanical simulations. The results demonstrate that the initiation and propagation of hot cracks are governed by the overlapping characteristics at the inter-pass and interlayer regions, which influence the formation of liquid films and localisation of the stress-strain concentration. Furthermore, the results revealed that the formation of stray grains and hot cracking mutually amplified each other. To address these challenges, a novel strategy for hot crack suppression is to optimise the dwell time at the inter-pass and interlayer regions to regulate the dendrite growth and elemental segregation. Consequently, a three-pass five-layer Ni-based single-crystal sample with a width of 2–3 mm was successfully prepared, which was free of cracks. Moreover, the hot crack suppression method was applied to single-pass thin-wall deposition, achieving a single-crystal structure with height exceeding 10 mm and a proportion of over 95 %. The repair quality surpassed the requirements for single-crystal blade repair. This study provides new insights into the thermal-mechanical mechanisms underlying hot cracking and establishes a scientific framework for mitigating the cracks in L-DED DD6 SX, thereby advancing their applicability in high-end component repair.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104283"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143912651","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Grindability and microstructural effect of nickel-based superalloys in magnetic field-assisted ultra-precision grinding","authors":"Te Zhao,&nbsp;Tengfei Yin,&nbsp;Dongbo Wu,&nbsp;Yi Tan,&nbsp;Denghui Li,&nbsp;Waisze Yip,&nbsp;Suet To","doi":"10.1016/j.ijmachtools.2025.104284","DOIUrl":"10.1016/j.ijmachtools.2025.104284","url":null,"abstract":"<div><div>The nickel-based superalloy Inconel 718 is essential in the aerospace and automotive industries due to its exceptional mechanical strength, fatigue resistance, and resistance to corrosion and oxidation. However, machining nickel-based alloys poses significant challenges in ultra-precision grinding (UPG), resulting in excessive grinding wheel vibration and poor surface quality. This study introduces an innovative magnetic field-assisted ultra-precision grinding (MFAUPG) technology, representing an advancement in the application of magnetic fields to assist grinding processes. A theoretical model was developed that links magnetic fields to grinding dynamics, elucidating the electromagnetic damping effects that significantly reduce wheel vibration and improve grinding performance. Experimental results reveal microstructural changes in Inconel 718 under magnetic field influence, including reduced grain size, deformation, and dislocation movement. Furthermore, the study elucidates the effects of magnetic fields on thermodynamics and recrystallization during the grinding process. These findings provide critical insights into the behavior of materials under magnetic field-assisted conditions, offering a promising solution to improve the grindability and surface integrity of difficult-to-machine nickel-based superalloys. The research underscores the potential of MFAUPG to achieve ultra-precision machining and enhance mechanical properties, thereby laying the groundwork for future innovations in economically sustainable grinding practices.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104284"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071189","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel suppressing evaporation method for enhancing micro-complex magnesium alloy parts additive manufacturing","authors":"Lin Su ,&nbsp;Xujiang Chao ,&nbsp;Jun Luo,&nbsp;Lei Zhao,&nbsp;Yi Zhou,&nbsp;Lewen Yang,&nbsp;Lehua Qi","doi":"10.1016/j.ijmachtools.2025.104281","DOIUrl":"10.1016/j.ijmachtools.2025.104281","url":null,"abstract":"<div><div>The increasing demand for micro-complex and customizable magnesium (Mg) alloy structures presents significant challenges for additive manufacturing (AM), particularly in controlling porosity and achieving high-dimensional accuracy. These challenges arise from bubble entrapment and explosive events caused by intense Mg evaporation. This study, for the first time, elucidates the fundamental mechanism underlying these defects, identifying spontaneous bubble nucleation and subsequent explosions within the melt pool as the root cause. In metal droplet-based AM (MDBM), experiments demonstrate that larger bubbles destabilize droplets and disrupt deposition trajectories due to intensified energy release, ultimately degrading print quality. To address this issue, a bubble nucleation and growth model, independent of specific Mg alloy AM methods, was developed. Based on this model, a novel strategy was proposed to mitigate Mg evaporation-induced defects. By identifying a critical bubble nucleation temperature, it was established that operating below this threshold completely suppresses bubble nucleation, thereby preventing associated defects. For conditions exceeding this temperature, the bubble growth model enables precise regulation of bubble size through process parameter optimization, effectively minimizing defects and enhancing structural integrity. As a result, the fabricated structures exhibit high dimensional precision and superior mechanical performance, characterized by pore-free microstructures, minimal dimensional deviation, and enhanced mechanical properties. This study introduces a parameter-driven method for suppressing Mg evaporation-induced defects across various Mg alloy AM technologies, with potential applicability to other highly evaporative metal AM processes. Moreover, it represents the first successful fabrication of micro-complex structures using highly evaporative metals, expanding the material selection for MDBM.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104281"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143892295","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Single-sensor-based reconstruction of force and displacement fields for thin-walled cylindrical shells milling","authors":"Jie Chen ,&nbsp;Haifeng Ma ,&nbsp;Qinghua Song ,&nbsp;Yukui Cai ,&nbsp;Zhanqiang Liu","doi":"10.1016/j.ijmachtools.2025.104282","DOIUrl":"10.1016/j.ijmachtools.2025.104282","url":null,"abstract":"<div><div>The cutting process of thin-walled cylindrical shells involves complex working conditions, and it is difficult to measure the cutting force and vibration displacement at the cutting point in real time. To address this issue, a method is proposed to reconstruct the force and displacement fields of the cylindrical shell in real time using only a single displacement sensor. Based on the first-order shear deformation theory and the artificial spring technique, the wave method can be employed to simultaneously obtain the natural frequencies and analytical mode shape functions of the cylindrical shell with elastic boundary. The dynamic behavior of the cylindrical shell is characterized by the superposition of mode shapes, thereby determining the force-displacement mapping relationship for the entire cylindrical shell. Utilizing in-situ measurement, the time-varying force and displacement fields are reconstructed in real time. Unlike existing methods for reconstructing the displacement field of thin-walled workpieces, one unique feature of this study is the simultaneous real-time reconstruction of the force and the displacement fields using single-point measurement information, providing higher reconstruction accuracy with fewer sensors, thus ensuring practicality and reliability of the results. Through simulation and experimental application to the force and displacement fields reconstruction of cylindrical shell under concentrated and moving force (e.g., cutting process), its practicality as a real-time tool for continuously monitoring cutting force and displacement of cylindrical shell during the cutting process has been demonstrated.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104282"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143904261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhanced strength-ductility synergy in laser directed energy deposited IN718 superalloys through heterogeneous deformation nanostructures","authors":"Yao Li ,&nbsp;Mengyang Li ,&nbsp;Hao Yang ,&nbsp;Xiaofeng Dang ,&nbsp;Luqing Cui ,&nbsp;Yang Jiao ,&nbsp;Zhiping Sun ,&nbsp;Ting Guo ,&nbsp;Weifeng He","doi":"10.1016/j.ijmachtools.2025.104280","DOIUrl":"10.1016/j.ijmachtools.2025.104280","url":null,"abstract":"<div><div>Laser directed energy deposition (LDED) shows great promise for repairing superalloy components of aeroengines but often results in coarse microstructures, porosity, and tensile residual stresses. Herein, post-process ultrasonic impact treatment (UIT) is adopted to effectively regulate the surface microstructure and residual stresses in LDED-fabricated IN718 superalloys, enhancing the strength-ductility synergy. The UIT process optimization is achieved through a systematic investigation of the effect of output powers on surface roughness, porosity, deformation microstructure, microhardness distribution, residual stress profile, and tensile behavior. Particularly, a finite element model for simulating residual stress field induced by ultrasonic impact is established, showcasing excellent agreement with experimental measurements. UIT-induced substantial dislocation and twinning activities result in depth-dependent heterogeneous deformation nanostructures, including alternating nano-grains and nano-laminated composite structures on the top surface (&lt;8 μm), dense nanotwins (∼30 μm depth), and substantial dislocation tangles and pile-ups (∼150 μm depth). Compared to untreated samples, the yield strength of the samples treated with optimal UIT parameters increased by ∼40%, with negligible ductility loss. The synergistic strengthening mechanisms are mainly attributed to the work hardening and boundary strengthening. To decouple these effects, a quantitative framework that correlates with depth-dependent dislocation populations and grain/nanotwin sizes is proposed, demonstrating good consistency with experimental measurements. The preserved ductility stems from a macroscopic deformation delocalization strategy facilitated by the hetero-deformation induced stress, compressive residual stress, and reduced porosity, together with the near-surface heterogeneous nanostructures enabling deformation accommodation at the micro-scale. This work elucidates the enhanced strength-ductility synergy through surface heterogeneous nanostructures and provides practical guidance for the additive manufacturing of high-performance materials.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104280"},"PeriodicalIF":14.0,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859343","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"On-line laser shielding of hydrogen-induced pores in arc-directed energy deposition","authors":"Qinghu Guo ,&nbsp;Yangyi Pan ,&nbsp;Yili Wang ,&nbsp;Shiwei Hua ,&nbsp;Ling Cen ,&nbsp;Ming Gao ,&nbsp;Xinyuan Jin ,&nbsp;Xianfeng Li ,&nbsp;Chen Zhang ,&nbsp;Sheng Liu","doi":"10.1016/j.ijmachtools.2025.104279","DOIUrl":"10.1016/j.ijmachtools.2025.104279","url":null,"abstract":"<div><div>The detrimental effects of pollutant elements in arc-directed energy deposition (arc-DED), particularly hydrogen-induced porosity in aluminum alloys, pose critical challenges for structural integrity. While pollutant shielding is commonly employed for pore suppression, the risk of hydrogen contamination from repeated remelting of deposited layers remains largely overlooked. This study revealed that even trace surface oxides on deposited layers critically governed hydrogen pore nucleation. Microstructural characterization demonstrated a synergistic clustering mechanism among oxides, hydrogen, and pores, where oxides act as dual-functional sites for hydrogen carriers and trappers. To address this, we developed an innovative on-line laser shielding-enhanced arc-DED system integrating a high-frequency nanosecond pulsed laser with arc plasma. This hybrid approach achieved in situ oxide purification within the molten pool, reducing porosity by 98.1 % compared to conventional arc-DED. The laser-arc synergy demonstrated amplified shielding efficiency, with the arc plasma enhancing laser-induced oxide removal rate by 9.6 times. Crucially, this technology disrupted the oxide-mediated hydrogen transportation pathway while eliminating hydrogen-trapping effects in the molten pool. Implementation in Al-Zn-Mg-Cu alloys significantly improves ductility by minimizing porosity at deformation-sensitive interlayer regions. Process scalability was further verified in Al-Mg alloys, achieving comparable porosity reduction. By decoupling the dual roles of oxides in hydrogen carriers and trappers, this work establishes a paradigm-shifting strategy for pore control in arc-DED, offering a versatile platform for processing hydrogen/oxygen-sensitive metals with enhanced mechanical performance.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104279"},"PeriodicalIF":14.0,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143851790","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards understanding the polishing behavior of thin anisotropic crystals: Coupling, discrepancy, and control across scales","authors":"Wei Gao ,&nbsp;Caoyang Xue ,&nbsp;Qi Sun ,&nbsp;Fang Han ,&nbsp;Bing-Feng Ju ,&nbsp;Li-tian Xuan ,&nbsp;Junjie Zhang ,&nbsp;Wule Zhu","doi":"10.1016/j.ijmachtools.2025.104269","DOIUrl":"10.1016/j.ijmachtools.2025.104269","url":null,"abstract":"<div><div>Thin anisotropic crystals (TACs) have potential applications in semiconductors, microelectronics, and aerospace. However, polishing a TAC workpiece with a compliant tool is highly challenging because of its susceptibility to deformation and brittle damage owing to its thin structure. Another significant challenge for polishing is the anisotropic discrepancy, which is highly dependent on the crystal planes/directions. To address these challenges and ultimately realize the process control of polishing a TAC workpiece, this study establishes a comprehensive multiscale modeling framework. The proposed framework analytically incorporates the macroscale tool–TAC interaction mechanics, macro/micro coupling material removal mechanism, and macro/micro coupling subsurface damage behavior according to the physical properties of a TAC workpiece. Experiments at different scales are conducted to validate notable discrepancies in the surface and subsurface material responses in the polishing of a TAC workpiece, agreeing well with analytical predictions. Based on the cross-scale study and framework, space- and time-domain control strategies are proposed, demonstrating the capability for effectively eliminating the anisotropic discrepancy from macro- to microscale and enabling deterministic control in the polishing of TACs.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104269"},"PeriodicalIF":14.0,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Defects in metal-forming: Formation mechanism, prediction and avoidance","authors":"Jun Ma ,&nbsp;Xuefeng Tang ,&nbsp;Yong Hou ,&nbsp;Heng Li ,&nbsp;Jianguo Lin ,&nbsp;M.W. Fu","doi":"10.1016/j.ijmachtools.2025.104268","DOIUrl":"10.1016/j.ijmachtools.2025.104268","url":null,"abstract":"<div><div>Defects in metal-forming create numerous bottleneck issues related to product quality, properties and performance, productivity, production cost, and sustainability. Effectively addressing defect issues in the up-front design process via prediction and avoidance of defect formation is the most critical and challenging issue in metal-forming based product development. In this paper, vital insights into defect classification, formation mechanisms, modelling/prediction, and avoidance principles and strategies in metal-forming are orchestrated and articulated. First, almost all the potential defects in metal-forming are exemplified and classified into three categories, viz., stress-induced, flow-induced, and microstructure-related defects. For each defect category, its influencing factors, formation mechanisms, and analysis approaches are delineated. Additionally, the countermeasures are articulated from the aspects of defect identification, control, avoidance or elimination by employing different state-of-the-art techniques, including in-process sensing/monitoring/detection, data-based modelling and online adaptive control. Finally, perspective insights into defect analysis, modelling/prediction, and avoidance are orchestrated and presented, focusing on innovative process developments, real-time in-process monitoring, physics-informed and data-driven through-process modelling, and strategies for intelligent and sustainable manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104268"},"PeriodicalIF":14.0,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143724294","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Particle floating and transfer effect in cored wire arc additive manufacturing: Formation mechanism and laser shock inhibition","authors":"Le Jia,&nbsp;Hao Yi,&nbsp;Furui Jiao,&nbsp;Huajun Cao","doi":"10.1016/j.ijmachtools.2025.104260","DOIUrl":"10.1016/j.ijmachtools.2025.104260","url":null,"abstract":"<div><div>Multi-material wire arc additive manufacturing (WAAM) presents a promising approach for fabricating high-end equipment components, with cored wire arc additive manufacturing (CWAAM) attracting significant interest. However, uneven particle distribution in CWAAM impedes technological advancement, as the mechanisms of particle flotation and its suppression remain unexplored. To address this issue, a novel nickel alloy cored wire incorporating TiC particles was developed, and the mechanism of particle flotation was investigated for the first time. The results indicate that the cored wire exhibits excellent formability, with particle flotation attributed to unstable droplet transfer, particle overflow along the side seam, and density differences. Furthermore, a laser shock-assisted CWAAM method was introduced to suppress particle flotation. Laser shock generated shock waves in the molten pool, inducing significant oscillations. Shock wave propagation altered molten pool flow dynamics and particle motion, effectively suppressing particle flotation and mitigating defects. This resulted in uniform particle dispersion in the deposited layer and facilitated particle size reduction. Additionally, laser shock eliminated porosity and fusion defects caused by particle flotation. The average grain size of the deposition layer decreased by 34.5 % and 23.3 % compared to solid wire arc additive manufacturing (SWAAM) and CWAAM, respectively, with a more random grain orientation. The average microhardness reached 394.8 HV_0.3, exceeding that of the other two methods, with no significant distribution differences. Yield strength, ultimate tensile strength, and elongation increased by 7.71 %, 5.37 %, and 12.71 % in the horizontal direction, and by 18.62 %, 6.63 %, and 13.03 % in the longitudinal direction, respectively, compared to conditions without laser shock, effectively reducing performance anisotropy. This innovative laser shock-assisted CWAAM method effectively mitigates weakened reinforcement effects and defects caused by particle flotation, thereby advancing WAAM toward large-scale, multi-material, and high-performance manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104260"},"PeriodicalIF":14.0,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143610192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Stable tongues induced by milling tool runout","authors":"David Hajdu ,&nbsp;Oier Franco ,&nbsp;Markel Sanz-Calle ,&nbsp;Giovanni Totis ,&nbsp;Jokin Munoa ,&nbsp;Gabor Stepan ,&nbsp;Zoltan Dombovari","doi":"10.1016/j.ijmachtools.2025.104258","DOIUrl":"10.1016/j.ijmachtools.2025.104258","url":null,"abstract":"<div><div>High material removal rates and performances are required for modern milling operations, which may trigger self-excited chatter vibrations. Such undesired vibrations cause unacceptable machined surface quality and premature deterioration of the cutting tool. After many decades of research and successful industrial solutions to this problem, some unexpected phenomena still arise, which put in doubt the effectiveness of well-known chatter theories and of the associated predictive numerical methods. Specifically, runout is a typically ignored consequence of inaccurate fixing of the tool, which has essential impact on the actual cutter-workpiece engagement and on the machined surface quality. The unequal engagement of cutter teeth change the dynamical behavior radically and prevent the application of classical simplifications in the modeling of milling processes. Moreover, in addition to the kinematically different teeth cycle-paths, the coexisting forced vibrations induce early fly-over effects of cutting edges creating new stability boundaries close to the resonant oscillations. This paper presents the underlying principles of this experienced phenomenon related to tool runout and its stabilization effect on chatter vibrations. Focusing on conventional milling cutters, the paper breaks with the widely held assumption that forced vibration has negligible effect on stability in the presence of tool runout. Initial laboratory experiments validate this tool irregularity induced phenomenon and industrial tests demonstrate the technical relevance of the results.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104258"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143548738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}