A Novel Updated Full-Discretization Method for Prediction of Milling Stability

Abstract

This paper presents an updated full-discretization method for milling stability prediction based on cubic spline interpolation. First, the mathematical model of the time-delay milling system considering regenerative chatter is represented by a dynamic delay differential equation. Then, in a single tooth passing period, the time is divided into a finite time intervals, the state item and the time-delay item are approximated in each time interval by cubic spline interpolation and third-order Newton interpolation, respectively. Afterward, a transition matrix is constructed to represent the transfer relationship of the teeth in a period. Finally, based on Floquet theory, the milling stability lobes can be obtained. Meanwhile, in order to improve computational efficiency, an optimized method is proposed based on the traditional algorithm and the proposed method has high precision without losing high efficiency. Finally, several milling experiments are conducted to verify the accuracy of the proposed method, and the results show that the predicted results agree well with the experimental results.