Milling Chatter Prevention by Adaptive Spindle Speed Tuning
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.
[1] 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.
[2] 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.
[3] Delio T., Tlusty J., Smith S. (1992) Use of audio signals for chatter
detection and control. Journal of Engineering for Industry 114: 146-157.
[4] 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.
[5] Altintas Y., Budak E. (1995) Analytical prediction of stability lobes in
milling. Annals of the CIRP 44: 1: 357-362.
[6] 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.
[7] 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.
[8] Ismail F., Ziaei R. (2002) Chatter suppression in five-axis machining of
flexible parts. International Journal of Machine Tools & Manufacture 42:
115-122.
[1] 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.
[2] 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.
[3] Delio T., Tlusty J., Smith S. (1992) Use of audio signals for chatter
detection and control. Journal of Engineering for Industry 114: 146-157.
[4] 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.
[5] Altintas Y., Budak E. (1995) Analytical prediction of stability lobes in
milling. Annals of the CIRP 44: 1: 357-362.
[6] 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.
[7] 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.
[8] Ismail F., Ziaei R. (2002) Chatter suppression in five-axis machining of
flexible parts. International Journal of Machine Tools & Manufacture 42:
115-122.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:59799", author = "Nan-Chyuan Tsai and Din-Chang Chen and Rong-Mao Lee and Bai-Lu Wang", title = "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.", keywords = "Chatter compensation, Stability lobes, Non-invasivemeasurement.", volume = "4", number = "2", pages = "233-6", }