Journal of Mechanical Engineering >

2018 , Vol. 54 >Issue 17: 85 - 93

DOI: https://doi.org/10.3901/JME.2018.17.085

Online Chatter Detection and Suppression System for Intelligent Machine Tool

  • XIONG Zhenhua ,
  • SUN Yuxin ,
  • DING Longyang
Expand
  • State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai 200240

Received date: 2017-09-11

  Revised date: 2017-12-09

  Online published: 2018-09-05

Fold

Abstract

In machining processes, chatter, as an unstable phenomenon, has been a major problem due to its adverse effects on productivity, surface finish and machine tool components. It is of great importance to avoid chatter and ensure the stable turning process. A real-time chatter detection and suppression system (CDSS) to avoid chatter in turning processes is presented. The weighted wavelet packet entropy is employed to monitor the turning process and it detects chatter in the premature stage. Once chatter is identified, the dominant chatter frequency is immediately estimated by the scale factor-based interpolated DFT. The spindle speed variation, which periodically modulates the spindle speed around a nominal value, is instantly activated to suppress chatter. The variation parameters, i.e. amplitude and frequency, are computed based on dominant chatter frequency. In this way, chatter can be automatically identified and suppressed in an online fashion before it has fully developed. To experimentally verify the proposed method, the end-face turning of a flexible disc is carried out on a numerical control lathe with Siemens 840D. Two turning experiments with and without the CDSS are conducted using the same cutting parameters, cutting tool and workpiece. Experimental results demonstrate that chatter can be automatically detected and suppressed by the CDSS before chatter arrives at fully developed stage.

Key words： intelligent manufacturing; chatter detection; chatter suppression; turning

Cite this article

XIONG Zhenhua , SUN Yuxin , DING Longyang . Online Chatter Detection and Suppression System for Intelligent Machine Tool[J]. Journal of Mechanical Engineering, 2018 , 54(17) : 85 -93 . DOI: 10.3901/JME.2018.17.085

References

[1] QUINTANA G,CIURANA J. Chatter in machining processes:A review[J]. International Journal of Machine Tools and Manufacture,2011,25(5):363-376.
[2] 王跃辉,王民. 金属切削过程颤振控制技术的研究进展[J]. 机械工程学报,2010,46(7):166-174. WANG Yuehui,WANG Min. Advances on machining chatter suppression research[J]. Journal of Mechanical Engineering,2010,46(7):166-174.
[3] YAO Zhehe,MEI Deqing,CHEN Zichen. On-line chatter detection and identification based on wavelet and support vector machine[J]. Journal of Materials Processing Technology,2010,210(5):713-719.
[4] 钱士才,孙宇昕,熊振华. 基于支持矢量机的颤振在线智能检测[J]. 机械工程学报,2015,51(20):1-8. QIAN Shicai,SUN Yuxin,XIONG Zhenhua. Support vector machine based online intelligent chatter detection[J]. Journal of Mechanical Engineering, 2015,51(20):1-8.
[5] LI X Q,WONG Y S,NEE A Y C. Tool wear and chatter detection using the coherence function of two crossed accelerations[J]. Journal of Manufacturing Science and Engineering,1997,37(4):425-435.
[6] GRABEC, GRADISEK J, GOVEKAR E. A new method for chatter detection in turning[J]. CIRP Ann-Manufacturing Technology, 1999, 48(1):29-32.
[7] NAIR U,KRISHNA B M,NAMBOOTHIRI V N N, NAMPOORI V P N. Permutation entropy based real-time chatter detection using audio signal in turning process[J]. International Journal of Advanced Manufacturing Technology,2010,46(1-4):61-68.
[8] PEREZ-CANALES D,ALVAREZ-RAMIREZ J, JAUREGUI-CORREA J C,et al. Identification of dynamic instabilities in machining process using the approximate entropy method[J]. International Journal of Machine Tools and Manufacture,2011,51(6):556-564.
[9] SUN Y X,ZHUANG C G,XIONG Z H. Real-time chatter detection using the weighted wavelet packet entropy[C]//Proceedings of IEEE/ASME International Conference on Advanced Intelligent Mechatronics,June 8-11, 2014, Besancon,France,2014:1652-1657.
[10] SUN Y X,XIONG Z H. An optimal weighted wavelet packet entropy method with application to real-time chatter detection[J]. IEEE Transactions on Mechatronics, 2016,21(4):2004-2014.
[11] TARNG Y S, KAO J Y, LEE E C. Chatter suppression in turning operations with a tuned vibration absorber[J]. Journal of Materials Processing Technology, 2000, 105(1):55-60.
[12] RUBIO L,LOYA J A,MIGUÉLEZ M H,et al. Optimization of passive vibration absorbers to reduce chatter in boring[J]. Mechanical Systems and Signal Processing,2013,41(1):691-704.
[13] 乔晓利,祝长生. 基于内置力执行器的铣削颤振的主动控制[J]. 机械工程学报,2012,48(1):185-192. QIAO Xiaoli,ZHU Changsheng. Active control of milling chatter based on the built-in force actuator[J]. Journal of Mechanical Engineering,2012,48(1):185-192.
[14] CHEN M, KNOSPE C R. Control approaches to the suppression of machining chatter using active magnetic bearings[J]. IEEE Transactions on Control Systems Technology,2007,15(2):220-232.
[15] LU X,CHEN F,ALTINTAS Y. Magnetic actuator for active damping of boring bars[J]. CIRP Annals-Manufacturing Technology,2014,63(1):369-372.
[16] MATSUBARA A,MAEDA M,YAMAJI I,Vibration suppression of boring bar by piezoelectric actuators and LR circuit[J]. CIRP Annals-Manufacturing Technology, 2014,63(1):373-376.
[17] YEH L J,LAI G J. A study of the monitoring and suppression system for turning slender workpieces[J]. Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,1995,209(3):227-236.
[18] LIN S C, HU M R. Low vibration control system in turning[J]. International Journal of Machine Tools and Manufacture,1992,32(5):629-640.
[19] WANG M,FEI R Y. On-line chatter detection and control in boring based on an electrorheological fluid[J]. Mechatronics,2001,11(7):779-792.
[20] BEDIAGA I,MUÑOA J, HERNÁNDEZ J,et al. An automatic spindle speed selection strategy to obtain stability in high-speed milling[J]. International Journal of Machine Tools and Manufacture,2009, 49(5):384-394.
[21] VAN DIJK N J M,DOPPENBERG E J J, FAASSEN R P H,et al. Automatic in-process chatter avoidance in the high-speed milling process[J]. Journal of Dynamic Systems, Measurement,and Control,2010,132(3):0310061-03100614.
[22] MORITA H,YAMASHITA T. Tracing and visualizing variation of chatter for in-process identification of preferred spindle speeds[J]. Procedia CIRP,2012,4:11-16.
[23] SUN Yuxin,ZHUANG Chungang,XIONG Zhenhua. A scale factor-based interpolated DFT for chatter frequency estimation[J]. IEEE Transactions on Instrumentation and Measurement,2015,64(10):2666-2678.
[24] SUN Yuxin,ZHUANG Chungang,XIONG Zhenhua. A switch-based interpolated DFT for small number of acquired sine-wave cycles[J]. IEEE Transactions on Instrumentation and Measurement,2016,65(4):846-85.
[25] AI-REGIB E,NI J. Chatter detection in machining using nonlinear energy operator[J]. Journal of Dynamic Systems, Measurement,and Control, Transactions of the ASME,2010,132(3):0345021-0345024.
[26] BAO S F,ZHANG W G,YU J Y,et al. A new approach to the early prediction of turning chatter[J]. Journal of Vibration and Acoustics, 1994, 116(4):485-488.
[27] TANSEL I N, DEMETGUL M, BICKRAJ K,et al. Basic computational tools and mechanical hardware for torque-based diagnostic of machining operations[J]. Journal of Intelligent Manufacturing,2013,24(1):147-161.
[28] AL-REGIB E,NI J,LEE S H. Programming spindle speed variation for machine tool chatter suppression[J]. International Journal of Machine Tools and Manufacture, 2003,43(12):1229-1240.
[19] ZHANG H,NI J. Internal energy based analysis on mechanism of spindle speed variation for regenerative chatter control[J]. Journal of Vibration and Control,2010,16(2):281-301.
[30] STOFERLE T,GRAB H. Vermeiden von ratterschwingungen durch periodische drehzahlanderung[J]. Werkstatt und Betrieb, 1972, 105:727-730. STOFERLE T,GRAB H. Avoid chatter vibrations by periodic speed change[J]. Workship and Operation,1972,105:727-730.
[31] INSPERGER T,STÉPÁN G. Chatter suppression of turning process via periodic modulation of the spindle speed-a 1 DOF analysis[C]//Proceedings of 3rd Conference on Mechanical Engineering, 2002, Budapest,Hungary,2002:720-724.
[32] LIN S C,DEVOR R E,KAPOOR S G. The effects of variable speed cutting on vibration control in face milling[J]. Journal of Engineering for Industry,1990, 112(1):1-11
[33] NIU J,DING Y,ZHU L M,et al. Stability analysis of milling processes with periodic spindle speed variation via the variable-step numerical integration method[J]. Journal of Manufacturing Science and Engineering, 2016,138(11):1145011-11450111.
[34] DE CANNIERE J,VAN BRUSSEL H, VAN BOGAERT J. A contribution to the mathematical analysis of variable spindle speed machining[J]. Applied Mathematical Modeling,1981,5(3):158-164.
[35] JAYARAM S,KAPOOR S,DEVOR R. Analytical stability analysis of variable spindle speed machining[J]. Journal of Manufacturing Science and Engineering, 2000,122(3):391-397.
[36] INSPERGER T,STÉPÁN G. Stability analysis of turning with periodic spindle speed modulation via semi-discretization[J]. Journal of Vibration and Control, 2004,10(12):1835-1855.
[37] MENG H F,KANG Y,CHEN Z,et al. Stability analysis and stabilization of a class of cutting systems with chatter suppression[J]. IEEE/ASME Transactions on Mechatronics,2015,20(2):991-996.
Options
Outlines

/

〈 〉

　 Copyright © Journal of Mechanical Engineering, All Rights Reserved.
Powered by Beijing Magtech Co. Ltd,.