Method for chatter detection with standard PLC systems

The aim of growing productivity together with increasing quality demands in machining leads to milling processes that are near their stability limits. The remaining stability reserves become smaller and the risk of unstable processing conditions like chatter increases. Unstable processes cause unwanted vibrations with high amplitudes in bearing loads. As a result, the lifetime of the bearings of the main spindle is reduced. Besides this, the surfaces of unstable processed work-pieces have unwanted chatter marks and do not fulfill the quality demands. To basically avoid unstable processing,a continuous monitoring of the process state is necessary. In this paper, a method for monitoring cutting processes using a standard programmable logic controller which is integrated in the drive controller of the machine tool spindle unit is presented. The method is real time-capable and based on the hypothesis that unstable process conditions result in a modulation of the amplitudes of the cutting forces. To detect this, an order tracking method is implemented, which uses a recursive parameter estimation algorithm together with inherently given signals of the drive controller. It is shown that the characteristic property of the used estimation algorithm and allowed aliasing lead to a reliable chatter detection even at sub-sampling. Finally some results of the first experimental investigation of the method are given.     

Active damping of chatter in the boring process via variable gain sliding mode control of a magnetorheological damper

In this article, a sliding mode control of a magnetorheological fluid damper is presented for active damping of chatter in the boring process for the first time. A boring bar is integrated with an in-house developed magnetorheological fluid damper system. The variable gain super twisting sliding mode control algorithm is designed and implemented for suppressing the chatter in the boring process. Simulations of the controller show its fast response and robustness against disturbances and parametric uncertainties. Validation cutting tests performed under various machining conditions showed that the stability limit can be increased significantly with the sliding mode control of the magnetorheological fluid damper.     

Chatter stability of thin-walled part machining using special end mills

Machining thin-walled structures introduces challenges in terms of process stability due to the varying in-process workpiece dynamics. For the first time in the literature, this study compares the effectiveness and performance of standard, variable-pitch, and crest-cut tools on chatter suppression in milling thin-walled parts. The novel stability maps are generated based on varying stability limits caused by in-process workpiece dynamics. Using the obtained stability maps, the performance of different cutting strategies is compared considering productivity and surface finish quality. The experimentally verified results demonstrate the superiority of crest-cut tools as a robust solution for overcoming chatter in thin-wall machining.     

Active control of high frequency chatter with machine tool feed drives in turning

This paper presents a new active vibration control strategy to mitigate high frequency regenerative chatter vibrations using machine tool feed drives. Rather than modal damping, proposed approach aims to control regenerative process dynamics to shape the Stability Lobe diagram (SLD) and attain higher material removal rates. The controller is designed as a feedback filter whose parameters are optimized to compensate regeneration. The proposed strategy is applied to actively control orthogonal (plunge) turning dynamics where >2.5 [kHz] chatter vibrations are suppressed by a fast tool servo (FTS) drive system. Stability lobes are shaped locally to reach up to 4x higher material removal rates.     

Chatter identification in end milling process using wavelet packets and Hilbert–Huang transform

Chatter detection is an important task to improve productivity and part quality in the machining process. Since measured signals from sensors are usually contaminated by background noise and other disturbances, it is necessary to find efficient signal processing algorithms to identify the chatter as soon as possible. This paper presents an effective chatter identification method for the end milling process based on the study of two advanced signal processing techniques, i.e., wavelet package transform (WPT) and Hilbert–Huang transform (HHT). The WPT works as a preprocessor to denoise the measured signals and hence the performance of the HHT is enhanced. The proposed method consists of four steps. First, the measured signals are decomposed by the WPT, so that the chatter signals are allocated in a certain frequency band. Secondly, wavelet packets with rich chatter information are selected and are used to reconstruct new signals. Thirdly, the reconstructed signals are analyzed with HHT to obtain a Hilbert–Huang spectrum, which is a full time–frequency–energy distribution of the signals. Finally, the mean value and standard deviation of the Hilbert–Huang spectrum are calculated to detect the chatter and identify its levels as well. The proposed method is applied to the end milling process and the experimental results prove that the method can identify the chatter effectively.     

Analysis of ultrasonic assisted machining (UAM) on regenerative chatter in turning

Ultrasonic assisted machining (UAM) is an advanced technology for improving the machining process, especially for hard materials. This paper presents an experimental and theoretical study toward the effect of UAM on chatter. Theoretical explanation of the effect of UAM on chatter is not fully presented in the available literature yet. In this paper, considering fixed tool geometry, theoretical dynamic equations for UAM are represented. The approach is demonstrated by deriving dynamic formulation of UAM in turning, considering both turning equation and Merchants ultrasonic machining equations. A time domain analysis is fulfilled on each machining condition to verify whether it has a stable vibration or an unstable chatter vibration. Subsequently, an experimental setup is designed and manufactured to investigate UAM effect on regenerative chatter. Special conical shape for workpiece is designed to experimentally generate different points of stability lobe. The generated oscillation by a piezoelectric actuator is transferred, amplified, and concentrated on the tip of the tool by appropriate design of a cutting tool, which is vibrated in its bending mode. The obtained results are encouraging, and indicating good agreement between experimental and theoretical results.     

基于观测器的压边装置自适应滑模同步控制

为了提高并联旋压机压边装置在外部扰动未知条件下的位置控制性能及抗干扰能力,提出了一种基于扰动观测器的自适应滑模同步控制方法。首先,针对电液比例位置控制系统存在未知扰动及部分参数无法预知的问题,设计了一种非线性扰动观测器,用以对扰动和未知参数进行估计和补偿。在此基础上设计了一种基于交叉耦合策略的滑模同步控制器,用以降低单液压缸位置误差及双液压缸同步误差,保证系统鲁棒性。此外,引入了一种滑模自适应趋近律,用以缩短滑模趋近时间,降低系统抖振。最后利用Lyapunov函数证明了控制系统的稳定性。仿真结果表明,所设计的控制器能够实现精确的同步位置控制,在持续扰动作用下仍然具有良好的性能。     

A comprehensive dynamic cutting force model for chatter prediction in turning

This paper presents a model of the dynamic cutting force process for the three-dimensional or oblique turning operation. To obtain dynamic force predictions, the mechanistic force model is linked to a tool–workpiece vibration model. Particular attention was paid to the inclusion of the cross-coupling between radial and axial vibrations in the force model. The inclusion of this cross-coupling facilitates prediction of the unstable–stable chatter phenomenon which usually occurs in certain cases of finish turning due to process non-linearity. The dynamic force model developed was incorporated into a computer program to obtain time-saving chatter predictions. Experimental tests were performed on AISI 4140 steel workpieces to justify the chatter predictions of the dynamic cutting process model in both the finishing and roughing regimes. Experimental results corroborate the unstable–stable chatter predictions of the model for different cases of finish machining. In addition, experimental results also confirmed the accuracy of chatter predictions for various cases of rough turning.     

Experimental research on cutting force variation during regenerative chatter vibration in a plain milling operation

A plain milling operation is characterized by a transient and intermittent cutting process, in which undeformed chip thickness varies continuously. The reverse is the case in variations of undeformed chip thickness in the processes of up- and down-milling. In the present study, the property of regenerative chatter vibration in a plain milling operation is investigated from the viewpoint of cutting force variation. With primary chatter vibration, the vibration energy supply is closely related to the collision of the cutting tool flank against the workpiece surface during vibration, which is induced by the bending vibration or the torsional vibration of the arbor. In addition to this factor, the regenerative effect is considered to be one of the main causes of the chatter excitation in regenerative chatter vibration. The simulation result of the cutting force variation during regenerative chatter vibration agrees well with the experimental result, when considering these factors. It is shown that the regenerative chatter vibration in the-down-milling process occurs more easily than in the up-milling process.     

A study on chatter boundaries of cylindrical plunge grinding with process condition-dependent dynamics

This paper presents a systematic study on the chatter characteristics of cylindrical plunge grinding processes. Chatter occurrence under a wide range of operating conditions is experimentally identified. The unique transient chatter behaviors during spark-in and spark-out of plunge grinding are also studied; and the transient chatter occurrence is separated from the steady-state chatter occurrence, which is used to define the chatter boundaries.It is shown that the measured structure dynamics of the wheel/workpiece exhibit strong dependency on grinding conditions. The dynamic/chatter model of cylindrical plunge grinding [H. Li, Y.C. Shin, A time-domain dynamic model for chatter prediction of cylindrical plunge grinding processes, ASME Journal of Manufacturing Science and Engineering 128(2) (2006) 404–415] is improved to handle the grinding force-dependent structure dynamics, and the modified model is validated by comparing the predicted chatter boundaries with experimental chatter conditions.     

On-line drilling chatter recognition and avoidance using an ART2—A neural network

In the paper, an adaptive resonance theory (ART2-A) neural network is applied to on-line recognition and avoidance of drilling chatter. It is shown that the ART2-A neural network can adaptively learn the features of the thrust force spectrum in a drilling process. As a result, drilling chatter can be automatically detected when a chatter feature starts to appear in the thrust force spectrum. Once chatter is detected, a spindle speed regulation method to suppress chatter is used. Experiments show that this new developed system can monitor and suppress drilling chatter efficiently even under varying cutting conditions.     

稳定控制理论在阳极焙烧炉中的应用

为对阳极焙烧炉温实施准确控制, 将无源性理论与过程控制相结合, 根据热力学消耗特性以及系统建模领域的行为性方法设计稳定的控制器. 控制点的设置采用分布式结构, 不同控制点的控制策略具有相同的结构, 同时考虑时间和空间上的分布特性. 仿真实验以已有的焙烧炉温度场模型为基础, 动态地为各个控制点提供设定值, 结果表明该方法可以非常有效地实现焙烧炉温度的有效控制.     

A parameters design approach to improve product quality and equipment performance in hot rolling

This study presents the application of parameters design to improve both the product quality and the equipment performance in a hot sheet rolling plant. Three empirical models were developed to predict and explain the relationship between variation in some process parameters and the type and range of product defects together with equipment disorders observed. The investigation is based on the analysis of the results of a set of designed experiments.The most critical process parameters were set at specified values and the effect of the change in these parameters, on rolled sheets quality and rolling equipment performance is evaluated. The three process parameters considered are the reduction ratio (Rd), the slab temperature (T_s), and the exit strip speed (Sp). The quality characteristics considered are: profile and flatness of rolled sheets and distance between chatter marks, the performance indicators considered are: rolling force, vibration measurements, and the rolling mill wear rate.Through optimization of process parameters, it was possible to reduce chattering. Consequently, chatter marks and roll wear were greatly reduced. Product flatness and profile were improved. Plant down time and production scrap was considerably reduced. This investigation proved that it is possible to improve both product quality and equipment performance in the hot rolling plant through the parameters design approach.     

Chatter stability of a slender cutting tool in turning with tool wear effect

An analysis of the chatter behavior for a slender cutting tool in turning in the presence of wear flat on the tool flank is presented in this research. The mechanism of a self-excited vibration development process with tool wear effect is studied. The components contributing to the forcing function in the turning vibration dynamics are analyzed in the context of cutting force and contact force. A comparison of the chatter stability for a fresh cutting tool and a worn cutting tool is provided. Stability plots are presented to relate width of cut to cutting velocity in the determination of chatter stability. Machining experiments at various conditions were conducted to identify the characteristic parameters involved in the vibration system and to identify the analytical stability limits. The theoretical result of chatter stability agrees qualitatively with the experimental result concerning the development of chatter stability model with tool wear effect.     

铅黄铜HPb59-1连续切削的颤振及其特征研究

试验研究了铅黄铜HPb59-1材料在连续切削加工时产生的切削颤振,得到了切屑形成频率与切削用量之间的关系,以及切削颤振形成频率和振幅。试验结果表明,铅黄铜HPb59-1材料因切削加工过程中周期性地产生剪裂型切屑而产生切削颤振。并由此总结得到铅黄铜HPb59-1材料加工产生的切削颤振所具有的一般性特征。     

Sound mapping for identification of stability lobe diagrams in milling processes

This paper deals with milling sound information. In milling operations, cutting edge impacts excite vibrations due to the interaction between the cutter and the workpiece, and because of the system's lack of dynamic stiffness. It is possible to distinguish between free, forced and self-excited vibrations. During a milling operation these three different types of mechanical vibrations propagate through air and generate a sound that intrinsically contains information about the process.A sound map is a graphical sound-level representation of a certain zone or region that is divided into points by means of a mesh. Sound maps have typically been used with social considerations in mind: to determine, for instance, noise levels in cities. The goal of this paper is to determine the stability lobe diagram (SLD) of a milling process by applying sound mapping methodology. Stability lobe diagrams show the stability frontier as combinations of spindle speeds (i.e. the abscissas axis) and radial depths of cut (i.e. the ordinate axis). In this investigation the SLD was obtained from a mesh of 30 spindle speeds per 20 axial depths of cut, resulting in a total of 600 experiments. A data acquisition platform was developed to collect the milling process sound through a microphone placed inside the machine-tool enclosure. Data were analysed off-line in order to recognise chatter frequencies.A 3D sound map was built by plotting, on each corresponding point of the mesh described above, the sound amplitude at frequencies around chatter frequency. The difference between stable and unstable zones is shown. This is the stability lobe diagram. The extensive experimentation detailed in this work reasserts and confirms the current state of knowledge of the chatter phenomenon.     

基于小波包和倒频谱分析的颤振特征提取方法

立铣加工过程中的颤振会严重影响工件表面质量和材料去除率,加剧刀具磨损和恶化工作环境。虽然大部分颤振监测系统可以监测到颤振发生,但颤振发生时已经对工件和刀具产生了严重的损伤,因此,需要提前监测到颤振特征。由于加工过程的非线性导致振动信号频率成分复杂,单一的时频分析方法难于得到可靠的颤振特征。通过小波包分解确定颤振发生频段并重构该频段信号,通过颤振发生频段的倒频谱辨识稳定、过渡和颤振状态。研究结果表明,该方法可以有效识别立铣加工过程的稳定、过渡和颤振状态。     

An expert troubleshooting system for the milling process

Common problems experienced in milling processes include forced and chatter vibrations, tolerance violations, chipping and premature wear of the tools. This paper presents an expert system which attempts to troubleshoot the source of milling problems by utilising dynamics data coupled with the opinion of the operator and acoustic Fourier spectrum data taken from the cutting process. The expert system utilises a fuzzy logic based process to interpret the signals and information, and recommends possible alterations to the process to achieve high-performance milling operations.Specific inference engines were developed to assess the chatter stability, variation in cutting force coefficient, tool run-out and forced vibration characteristics of the system. Lastly, a stability lobe plot interpretation engine to automate the lobe selection process and recommend new, chatter free cutting conditions, was also developed. The chatter stability inference engine was tested with real cutting data, through acoustic measurements taken from various cutting conditions on an aluminium milling process. The chatter inference engine successfully determined the stability of the system for each sampled cutting condition. The robustness of the troubleshooting system depends on the accuracy of acoustic and frequency response measurements.     

Review of chatter studies in cold rolling

In the past, many different modes of vibration and causes of rolling chatter have been presented, yet no complete and clear picture of the basic mechanics emerged. In order to control chatter in cold rolling operations, a much better understanding of the basic mechanics of the problem is required. To provide, therefore, a ground work for developing such a basic understanding, in this paper, existing models of a mill stand as well as of the rolling process in the open literature are presented. In addition, existing chatter models, which are formulated to investigate chatter as the consequence of the interaction between the structural dynamics of the mills and the dynamics of the rolling process, are also reviewed.     

Prediction of regenerative chatter by modelling and analysis of high-speed milling

High-speed milling is widely used in the manufacturing industry. For the efficiency of the milling process, high demands on the material removal rate and the surface generation rate are posed. The process parameters, determining these two rates, are restricted by the occurrence of regenerative chatter. Chatter is an undesired instability phenomenon, which causes both a reduced product quality and rapid tool wear. In this paper, the milling process is modelled, based on dedicated experiments on both the material behaviour of the workpiece material and the machine dynamics. These experiments show that both the material properties and the machine dynamics are dependent on the spindle speed. Furthermore, a method for the prediction of the chatter boundaries is proposed and applied in order to predict the chatter boundaries as a function of process parameters, such as spindle speed and depth-of-cut, for spindle speed varying material and machine parameters. Finally, experiments are performed to estimate these chatter boundaries in practice. The modelled chatter boundaries are compared to the experimental results in order to validate the model and the stability analysis.