{"title":"Milling Chatter Prevention by Adaptive Spindle Speed Tuning","authors":"Nan-Chyuan Tsai, Din-Chang Chen, Rong-Mao Lee, Bai-Lu Wang","volume":38,"journal":"International Journal of Mechanical and Mechatronics Engineering","pagesStart":218,"pagesEnd":224,"ISSN":"1307-6892","URL":"https:\/\/publications.waset.org\/pdf\/10746","abstract":"This paper presents how the real-time chatter\r\nprevention can be realized by feedback of acoustic cutting signal, and\r\nthe efficacy of the proposed adaptive spindle speed tuning algorithm is\r\nverified by intensive experimental simulations. A pair of\r\nmicrophones, perpendicular to each other, is used to acquire the\r\nacoustic cutting signal resulting from milling chatter. A real-time\r\nfeedback control loop is constructed for spindle speed compensation\r\nso that the milling process can be ensured to be within the stability\r\nzone of stability lobe diagram. Acoustic Chatter Signal Index (ACSI)\r\nand Spindle Speed Compensation Strategy (SSCS) are proposed to\r\nquantify the acoustic signal and actively tune the spindle speed\r\nrespectively. By converting the acoustic feedback signal into ACSI,\r\nan appropriate Spindle Speed Compensation Rate (SSCR) can be\r\ndetermined by SSCS based on real-time chatter level or ACSI.\r\nAccordingly, the compensation command, referred to as Added-On\r\nVoltage (AOV), is applied to increase\/decrease the spindle motor\r\nspeed. By inspection on the precision and quality of the workpiece\r\nsurface after milling, the efficacy of the real-time chatter prevention\r\nstrategy via acoustic signal feedback is further assured.","references":"[1] Lange J. H., Abu-Zahra N. H. (2002) Tool chatter monitoring in turning\r\noperations using wavelet analysis of ultrasound waves. International\r\nJournal of Advanced Manufacturing Technology 20: 4: 248-254.\r\n[2] Khalifa O. O., Densibali A., Faris W. (2006) Image processing for chatter\r\nidentification in machining processes. International Journal of Advanced\r\nManufacturing Technology 31: 5-6: 443-449.\r\n[3] Delio T., Tlusty J., Smith S. (1992) Use of audio signals for chatter\r\ndetection and control. Journal of Engineering for Industry 114: 146-157.\r\n[4] Soliman E., Ismail F. (1998) A control system for chatter avoidance by\r\nramping the spindle speed. Journal of Manufacturing Science and\r\nEngineering 120: 674-683.\r\n[5] Altintas Y., Budak E. (1995) Analytical prediction of stability lobes in\r\nmilling. Annals of the CIRP 44: 1: 357-362.\r\n[6] Faassen R. P. H., Wouw N. V. D., Oosterling J.A.J., Nijmeijer H. (2003)\r\nPrediction of regenerative chatter by modeling and analysis of high-speed\r\nmilling. International Journal of Machine Tools & Manufacture 43:\r\n1437-1446.\r\n[7] Solis E., Peres C. R., Jimenez J. E., Alique J. R., Monje J. C. (2004) A new\r\nanalytical-experimental method for the identification of stability lobes in\r\nhigh-speed milling. International Journal of Machine Tools &\r\nManufacture 44: 1591-1597.\r\n[8] Ismail F., Ziaei R. (2002) Chatter suppression in five-axis machining of\r\nflexible parts. International Journal of Machine Tools & Manufacture 42:\r\n115-122.","publisher":"World Academy of Science, Engineering and Technology","index":"Open Science Index 38, 2010"}