Technical Brief

Chatter Avoidance in Parallel Turning With Unequal Pitch Angle Using Observer-Based Cutting Force Estimation

[+] Author and Article Information
Shinya Sakata

Keio University,
Yokohama, Kanagawa 223-8522, Japan
e-mail: sakata@ams.sd.keio.ac.jp

Takashi Kadota

Keio University,
Yokohama, Kanagawa 223-8522, Japan
e-mail: kadota@ams.sd.keio.ac.jp

Yuki Yamada

Keio University,
Yokohama, Kanagawa 223-8522, Japan
e-mail: yamada@ams.sd.keio.ac.jp

Kenichi Nakanishi

Nakamura-Tome Precision Industry Co., Ltd.,
Hakusan, Ishikawa 920-2195, Japan
e-mail: kenichi-nakanishi@nakamura-tome.co.jp

Hayato Yoshioka

FIRST, Tokyo Institute of Technology,
Meguro, Tokyo 152-8550, Japan
e-mail: yoshioka.h.aa@m.titech.ac.jp

Norikazu Suzuki

Nagoya University,
Nagoya, Aiti 464-0814, Japan
e-mail: nsuzuki@mech.nagoya-u.ac.jp

Yasuhiro Kakinuma

Keio University,
Yokohama, Kanagawa 223-8522, Japan
e-mail: kakinuma@sd.keio.ac.jp

Manuscript received June 12, 2017; final manuscript received January 10, 2018; published online February 14, 2018. Assoc. Editor: Satish Bukkapatnam.

J. Manuf. Sci. Eng 140(4), 044501 (Feb 14, 2018) (7 pages) Paper No: MANU-17-1367; doi: 10.1115/1.4039111 History: Received June 12, 2017; Revised January 10, 2018

Parallel turning is garnering attention as one of the most important technologies for multitasking machine tools. This is because a potential exists to enhance the stability limits compared to the turning operation using a single tool when cutting conditions are properly selected. Although stability prediction models for parallel turning have been developed in recent years, in-process monitoring and in-process chatter techniques are almost not discussed. In this study, to suppress chatter vibration, an unequal pitch turning method was proposed. In this method, the upper tool was controlled based on the optimum pitch angle calculated from spindle speed and chatter frequency. Chatter frequency was identified from estimated cutting force by a disturbance observer (DOB). From the result of the parallel turning test, it is clear that chatter vibration can be avoided by controlling the upper tool based on optimum pitch angle. Meanwhile, the pitch angle difference that can suppress chatter had a certain range. Subsequently, the robustness of the optimum pitch angle difference is experimentally evaluated by both the continuous moving test and the stepwise moving test of the pitch angle.

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Fig. 1

Prototype of multitasking machine tool: (a) front view and (b) system configuration

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Fig. 2

Dual-inertia model of ball-screw driven stage in the X direction

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Fig. 3

Comparison of parallel turning method: (a) equal pitch turning and (b) unequal pitch turning

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Fig. 4

Each cutting tool left on the wavy surface

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Fig. 5

Experimental setup for cutting tests

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Fig. 6

Frequency response of workpiece at tip

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Fig. 7

Time-frequency domain data of estimated cutting force at equal pitch turning

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Fig. 8

Time-frequency domain data of estimated cutting force at unequal pitch turning

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Fig. 9

Machined surface of workpiece: (a) equal pitch turning and (b) unequal pitch turning

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Fig. 10

Schematic diagram of tool motion

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Fig. 11

Experimental result under continuous movement of pitch angle: (a) time-frequency analysis result of estimated cutting force and (b) motion trajectory of the tool 1 in the X-axis

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Fig. 12

Time-frequency analysis results of estimated cutting force under various phase shift

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Fig. 13

Relationship between phase difference and machined surface




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