Sensor-less on-line chatter detection in turning process based on phase monitoring using power factor theory

Shuntaro Yamato, Takayuki Hirano, Yuki Yamada, Ryo Koike, Yasuhiro Kakinuma

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

This paper presents a sensor-less on-line chatter detection method for a turning process by introducing a mechanical energy factor (MEF) and a mechanical power factor (MPF). The MEF and MPF serve as indexes for self-excited chatter and forced chatter, respectively. The indexes are based on the power-factor theory, which generally represents the electrical-power efficiency as having a correlation with the phase difference between the current and the voltage. By applying this theory to a mechanical system, the MEF and MPF can be employed to monitor the phase difference between the cutting force and the displacement/velocity of the tool system, respectively. By monitoring the phase difference, chatter vibration can be detected in time domain with a high response and small number of computations. The MEF and MPF can be calculated without using additional external sensors employing the sensor-less cutting-force estimation technique based on the disturbance observer. The monitoring performance of the proposed method was evaluated through several outside turning tests with a prototype precision lathe. The results showed that both the self-excited and forced chatters were successfully detected with unique thresholds, which did not depend on the cutting condition or the workpiece material.

Original languageEnglish
JournalPrecision Engineering
DOIs
Publication statusAccepted/In press - 2017

Fingerprint

Monitoring
Sensors
Electric potential

Keywords

  • Chatter detection
  • Disturbance observer
  • Power factor
  • Turning

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Sensor-less on-line chatter detection in turning process based on phase monitoring using power factor theory. / Yamato, Shuntaro; Hirano, Takayuki; Yamada, Yuki; Koike, Ryo; Kakinuma, Yasuhiro.

In: Precision Engineering, 2017.

Research output: Contribution to journalArticle

@article{9f2b61d24774412681f68b1bcc42ac91,
title = "Sensor-less on-line chatter detection in turning process based on phase monitoring using power factor theory",
abstract = "This paper presents a sensor-less on-line chatter detection method for a turning process by introducing a mechanical energy factor (MEF) and a mechanical power factor (MPF). The MEF and MPF serve as indexes for self-excited chatter and forced chatter, respectively. The indexes are based on the power-factor theory, which generally represents the electrical-power efficiency as having a correlation with the phase difference between the current and the voltage. By applying this theory to a mechanical system, the MEF and MPF can be employed to monitor the phase difference between the cutting force and the displacement/velocity of the tool system, respectively. By monitoring the phase difference, chatter vibration can be detected in time domain with a high response and small number of computations. The MEF and MPF can be calculated without using additional external sensors employing the sensor-less cutting-force estimation technique based on the disturbance observer. The monitoring performance of the proposed method was evaluated through several outside turning tests with a prototype precision lathe. The results showed that both the self-excited and forced chatters were successfully detected with unique thresholds, which did not depend on the cutting condition or the workpiece material.",
keywords = "Chatter detection, Disturbance observer, Power factor, Turning",
author = "Shuntaro Yamato and Takayuki Hirano and Yuki Yamada and Ryo Koike and Yasuhiro Kakinuma",
year = "2017",
doi = "10.1016/j.precisioneng.2017.07.017",
language = "English",
journal = "Precision Engineering",
issn = "0141-6359",
publisher = "Elsevier Inc.",

}

TY - JOUR

T1 - Sensor-less on-line chatter detection in turning process based on phase monitoring using power factor theory

AU - Yamato, Shuntaro

AU - Hirano, Takayuki

AU - Yamada, Yuki

AU - Koike, Ryo

AU - Kakinuma, Yasuhiro

PY - 2017

Y1 - 2017

N2 - This paper presents a sensor-less on-line chatter detection method for a turning process by introducing a mechanical energy factor (MEF) and a mechanical power factor (MPF). The MEF and MPF serve as indexes for self-excited chatter and forced chatter, respectively. The indexes are based on the power-factor theory, which generally represents the electrical-power efficiency as having a correlation with the phase difference between the current and the voltage. By applying this theory to a mechanical system, the MEF and MPF can be employed to monitor the phase difference between the cutting force and the displacement/velocity of the tool system, respectively. By monitoring the phase difference, chatter vibration can be detected in time domain with a high response and small number of computations. The MEF and MPF can be calculated without using additional external sensors employing the sensor-less cutting-force estimation technique based on the disturbance observer. The monitoring performance of the proposed method was evaluated through several outside turning tests with a prototype precision lathe. The results showed that both the self-excited and forced chatters were successfully detected with unique thresholds, which did not depend on the cutting condition or the workpiece material.

AB - This paper presents a sensor-less on-line chatter detection method for a turning process by introducing a mechanical energy factor (MEF) and a mechanical power factor (MPF). The MEF and MPF serve as indexes for self-excited chatter and forced chatter, respectively. The indexes are based on the power-factor theory, which generally represents the electrical-power efficiency as having a correlation with the phase difference between the current and the voltage. By applying this theory to a mechanical system, the MEF and MPF can be employed to monitor the phase difference between the cutting force and the displacement/velocity of the tool system, respectively. By monitoring the phase difference, chatter vibration can be detected in time domain with a high response and small number of computations. The MEF and MPF can be calculated without using additional external sensors employing the sensor-less cutting-force estimation technique based on the disturbance observer. The monitoring performance of the proposed method was evaluated through several outside turning tests with a prototype precision lathe. The results showed that both the self-excited and forced chatters were successfully detected with unique thresholds, which did not depend on the cutting condition or the workpiece material.

KW - Chatter detection

KW - Disturbance observer

KW - Power factor

KW - Turning

UR - http://www.scopus.com/inward/record.url?scp=85027408195&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=85027408195&partnerID=8YFLogxK

U2 - 10.1016/j.precisioneng.2017.07.017

DO - 10.1016/j.precisioneng.2017.07.017

M3 - Article

JO - Precision Engineering

JF - Precision Engineering

SN - 0141-6359

ER -