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.