Multi harmonic spindle speed variation for milling chatter suppression and parameters optimization

A method for varying the spindle speed using chaotic signal to suppress chatter in machining is developed. The effects of spindle speed variation on cutting chatter control between using chaotic and sinusoidal signals were analyzed by simulation and experimental methods. Various chaotic codes are used in the chatter suppression process, and it is found that LORENZ-1 code results in the smallest machine noise.

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Online Chatter Suppression in Turning by Adaptive Amplitude Modulation of Spindle Speed Variation

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4041248 ◽

2018 ◽

Vol 140 (12) ◽

Cited By ~ 9

Author(s):

Longyang Ding ◽

Yuxin Sun ◽

Zhenhua Xiong

Keyword(s):

Wavelet Packet ◽

Bootstrap Method ◽

Threshold Value ◽

Spindle Speed ◽

Speed Variation ◽

Model Free ◽

Chatter Suppression ◽

Spindle Speed Variation ◽

Model Free Controller

Although the effectiveness of spindle speed variation (SSV) method in chatter suppression has been extensively reported, the determination of optimal SSV parameters remains a challenge owing to the difficulties in obtaining accurate modal parameters especially under varying cutting conditions. This paper proposes a closed-loop SSV cutting system to suppress chatter in turning. The dimensionless SSV amplitude is adaptively adjusted with a model-free controller to accommodate change of the chatter level. The wavelet packet entropy (WPE) is computed online to evaluate quantitatively the machining state, and a predetermined chatter threshold is used to calculate the controller input. Energy-based analysis of SSV parameters effect on chatter shows that the amplitude is the more dominant parameter than the frequency. Then we introduce the scheme of the proposed chatter suppression system, where the Bootstrap method is adopted to determine the threshold value. Next, the feasibility of the proposed method for chatter suppression is tested by simulations with different cutting depths. Finally, comparisons of experimental results verify the conclusion of theoretical analysis about the effect of SSV parameters, and two cutting tests with diverse activating strategies are performed to validate the effectiveness of the proposed system for chatter suppression in turning.

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Investigation of Correlation Between Process Energy Balance and Phase Shift Variation of Chatter Vibration in Spindle Speed Variation

JSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing ◽

10.1115/lemp2020-8565 ◽

2020 ◽

Author(s):

Shuntaro Yamato ◽

Hirohiko Matsuzaki ◽

Takamichi Ito ◽

Yasuhiro Kakinuma

Keyword(s):

Energy Balance ◽

Phase Shift ◽

Spindle Speed ◽

Chatter Vibration ◽

Simple Task ◽

Speed Variation ◽

Chatter Suppression ◽

Spindle Speed Variation ◽

Total Energy Balance ◽

Process Energy

Abstract It is widely known that the spindle speed variation (SSV) is an effective technology for chatter suppression, especially in the turning or boring process. Its simple optimal design, however, is not a simple task. In the past, certain research works considered the chatter onset from the perspective of process energy balance in a vibration cycle. The phase shift between previous (i.e., outer modulation) and present vibrations (i.e., inner modulation) of chatter is a key factor in the process energy balance. The SSV can be conceptually interpreted as a technique that continuously perturbs the phase shift between the inner and outer modulations, thereby changing the process energy balance. Simply put, the chatter energy can be controlled by applying the SSV to suppress the chatter. This study investigates the correlation between the process energy balance and phase shift behavior in the sinusoidal SSV through numerical energy simulation. The results indicate that the phase shift at the maximum spindle speed is an important factor to minimize the total energy balance (i.e., to dissipate the chatter energy) in the SSV cycle. This probably corresponds to the fact that the beat vibration tends to occur near the maximum spindle speed in the SSV. The insights gained from this study are anticipated to serve as a guideline for shaping the phase shift profile in the SSV to effectively suppress chatter vibration.

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Machine-Tool Chatter Suppression by Multi-Level Random Spindle Speed Variation

10.1115/imece1999-0755 ◽

1999 ◽

Author(s):

Alpay Yilmaz ◽

Emad AL-Regib ◽

Jun Ni

Keyword(s):

Spindle Speed ◽

New Method ◽

Spindle System ◽

Speed Variation ◽

Chatter Suppression ◽

Random Fashion ◽

Spindle Speed Variation ◽

Machine Tool Chatter ◽

Multi Level ◽

The Stability

Abstract This paper presents a new method for varying the spindle speed to suppress chatter in machining. The spindle speed is varied in pseudo-random fashion within the bandwidth of the spindle system. Both implementation issues and spindle system responses to such signals are investigated. A new method to analyze the stability of machining systems with varying spindle speed is also introduced. The effectiveness and advantages of the random spindle speed variation in chatter suppression is verified using numerical simulations and experiments.

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Machine Tool Chatter Suppression by Multi-Level Random Spindle Speed Variation

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1378794 ◽

2002 ◽

Vol 124 (2) ◽

pp. 208-216 ◽

Cited By ~ 56

Author(s):

Alpay Yilmaz ◽

Emad AL-Regib ◽

Jun Ni

Keyword(s):

Spindle Speed ◽

New Method ◽

Spindle System ◽

Speed Variation ◽

Chatter Suppression ◽

Random Fashion ◽

Spindle Speed Variation ◽

Machine Tool Chatter ◽

Multi Level ◽

The Stability

This paper presents a new method for varying the spindle speed to suppress chatter in machining. The spindle speed is varied in a pseudo-random fashion within the bandwidth of the spindle system. Both implementation issues and spindle system responses to such signals are investigated. A new method to analyze the stability of machining systems with varying spindle speed is also introduced. The effectiveness and advantages of the random spindle speed variation in chatter suppression is verified using numerical simulations and experiments.

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Active Chatter Suppression in Turning by Simultaneous Adjustment of Amplitude and Frequency of Spindle Speed Variation

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4045618 ◽

2019 ◽

Vol 142 (2) ◽

Cited By ~ 4

Author(s):

Longyang Ding ◽

Yuxin Sun ◽

Zhenhua Xiong

Keyword(s):

Removal Rate ◽

Dimensional Accuracy ◽

Spindle Speed ◽

Machining Processes ◽

Speed Variation ◽

Chatter Suppression ◽

Spindle Speed Variation ◽

Simultaneous Adjustment ◽

Adaptively Adjusting ◽

Suppression Strategy

Abstract In machining processes, chatter suppression is very important for achieving a high material removal rate, good dimensional accuracy, and surface finish. With the merits of effectiveness and easy implementation, spindle speed variation (SSV) is regarded as a promising approach for chatter suppression. However, there is little research on the selection of SSV parameters for adaptive chatter suppression. Although the effectiveness of adaptively adjusting SSV amplitudes has been recently examined, the simultaneous adjustment of the SSV amplitude and frequency is expected to exhibit stronger adaptability since it achieves greater flexibility. In this paper, an active chatter suppression strategy is presented by simultaneously adjusting the amplitude and frequency of spindle speed variation. The effect of SSV parameters on stability improvement in turning processes including the tool wear is first investigated to demonstrate the necessity of simultaneously adjusting the amplitude and frequency for chatter suppression. Then, the proposed chatter suppression system is introduced, where two SSV parameters are simultaneously adjusted with optimal fractional-order proportional integral differential (FOPID) controllers to keep the chatter indicator close to a target value. Moreover, the FOPID controller is optimally tuned with the JADE algorithm. The effectiveness of the proposed method is verified by comparing simulated results of different SSV parameters adjusting strategies. Finally, machining tests are conducted to validate that the proposed chatter suppression method outperforms the existing SSV method in flexibility and effectiveness.

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Simulation for Sinusoidal Spindle Speed Variation Cutting in Time Domain Based on Simulink

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.188.549 ◽

2011 ◽

Vol 188 ◽

pp. 549-554

Author(s):

Kuan Min Mao ◽

Min Zhang ◽

Ming Zhu ◽

Ling Yin

Keyword(s):

Time Domain ◽

Amplitude Ratio ◽

Block Diagram ◽

Spindle Speed ◽

Chatter Vibration ◽

Speed Variation ◽

Chatter Suppression ◽

Spindle Speed Variation ◽

Machine Tool Chatter ◽

Nonlinear Mechanical

This paper presents a simulink block diagram which is constructed on the basis of a classical nonlinear mechanical model of machine tool chatter vibration. With varying amplitude ratio and frequency ,sinusoidal spindle speed variation (S3V) cutting process is investigated in time domain, which tests and verifies the feasibility of chatter suppression by S3V method.

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