Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Shuntaro Yamato, Kenichi Nakanishi, Norikazu Suzuki, Yasuhiro Kakinuma

Research output: Contribution to journalArticlepeer-review

3 Citations (Scopus)

Abstract

To maximize the potential for high material removal rates in simultaneous processes such as parallel milling, developing strategies for successful chatter suppression/avoidance is an important concern for manufacturers. In this study, the effectiveness of the spindle speed difference method (SDM) for chatter suppression is discussed in a parallel end-milling process where a flexible workpiece is machined by two tools rotating in opposite direction. The process model is developed, considering that the dynamic variation due to the regenerative effect occurs on a plane perpendicular to the tool axis direction. Through the process simulations and the experiments, this study provides informative discussion for comprehending the process behavior. Additionally, a real-time active chatter suppression system with adaptive SDM, where the spindle speed difference is sequentially optimized during the process according to the tracked chatter frequency, is developed by integrating a chatter monitoring system based on sensorless cutting force estimation with sliding discrete Fourier transform. The results show that the developed real-time adaptive system of spindle speed suppresses chatter vibrations more effectively than non-adaptive SDM system; hence, the integrated system can contribute self-optimizing machining systems oriented to Industry 4.0.

Original languageEnglish
Pages (from-to)227-240
Number of pages14
JournalInternational Journal of Precision Engineering and Manufacturing
Volume22
Issue number2
DOIs
Publication statusPublished - 2021 Feb

Keywords

  • Chatter
  • Disturbance observer
  • Parallel milling
  • Process control
  • Speed difference method

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering
  • Electrical and Electronic Engineering

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