Commenced in January 2007
Paper Count: 31837
Milling Chatter Prevention by Adaptive Spindle Speed Tuning
Abstract:This paper presents how the real-time chatter prevention can be realized by feedback of acoustic cutting signal, and the efficacy of the proposed adaptive spindle speed tuning algorithm is verified by intensive experimental simulations. A pair of microphones, perpendicular to each other, is used to acquire the acoustic cutting signal resulting from milling chatter. A real-time feedback control loop is constructed for spindle speed compensation so that the milling process can be ensured to be within the stability zone of stability lobe diagram. Acoustic Chatter Signal Index (ACSI) and Spindle Speed Compensation Strategy (SSCS) are proposed to quantify the acoustic signal and actively tune the spindle speed respectively. By converting the acoustic feedback signal into ACSI, an appropriate Spindle Speed Compensation Rate (SSCR) can be determined by SSCS based on real-time chatter level or ACSI. Accordingly, the compensation command, referred to as Added-On Voltage (AOV), is applied to increase/decrease the spindle motor speed. By inspection on the precision and quality of the workpiece surface after milling, the efficacy of the real-time chatter prevention strategy via acoustic signal feedback is further assured.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1075826Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1557
 Lange J. H., Abu-Zahra N. H. (2002) Tool chatter monitoring in turning operations using wavelet analysis of ultrasound waves. International Journal of Advanced Manufacturing Technology 20: 4: 248-254.
 Khalifa O. O., Densibali A., Faris W. (2006) Image processing for chatter identification in machining processes. International Journal of Advanced Manufacturing Technology 31: 5-6: 443-449.
 Delio T., Tlusty J., Smith S. (1992) Use of audio signals for chatter detection and control. Journal of Engineering for Industry 114: 146-157.
 Soliman E., Ismail F. (1998) A control system for chatter avoidance by ramping the spindle speed. Journal of Manufacturing Science and Engineering 120: 674-683.
 Altintas Y., Budak E. (1995) Analytical prediction of stability lobes in milling. Annals of the CIRP 44: 1: 357-362.
 Faassen R. P. H., Wouw N. V. D., Oosterling J.A.J., Nijmeijer H. (2003) Prediction of regenerative chatter by modeling and analysis of high-speed milling. International Journal of Machine Tools & Manufacture 43: 1437-1446.
 Solis E., Peres C. R., Jimenez J. E., Alique J. R., Monje J. C. (2004) A new analytical-experimental method for the identification of stability lobes in high-speed milling. International Journal of Machine Tools & Manufacture 44: 1591-1597.
 Ismail F., Ziaei R. (2002) Chatter suppression in five-axis machining of flexible parts. International Journal of Machine Tools & Manufacture 42: 115-122.