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Research Papers

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

[+] Author and Article Information
Longyang Ding

State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: medinglongyang@sjtu.edu.cn

Yuxin Sun

State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: sunyuxinhe@sjtu.edu.cn

Zhenhua Xiong

State Key Laboratory of Mechanical System
and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: mexiong@sjtu.edu.cn

1Corresponding author.

Manuscript received June 4, 2018; final manuscript received August 16, 2018; published online September 17, 2018. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 140(12), 121003 (Sep 17, 2018) (11 pages) Paper No: MANU-18-1384; doi: 10.1115/1.4041248 History: Received June 04, 2018; Revised August 16, 2018

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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Copyright © 2018 by ASME
Topics: Machining , Chatter , Cutting
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References

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Figures

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Fig. 1

Net work done by the cutting force for variable speed machining with different combinations of SSV parameters

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Fig. 2

Net work done by the regenerative force with respect to RVA and RVF using cutting parameters in Ref. [22]

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Fig. 3

Scheme for chatter suppression system by adaptively adjusting SSV amplitudes based on the PID controller

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Fig. 4

Simulation model of chatter suppression in turning by adaptively adjusting the SSV amplitude in Simulink

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Fig. 5

Threshold determination for chatter detection by the MBB method

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Fig. 6

Simulation results of the cutting process for (a) case 1 at h0 = 0.2 mm and (b) case 2 at h0 = 0.26 mm

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Fig. 7

Experimental setup of the proposed closed-loop SSV cutting system

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Fig. 8

Experimental comparisons from SSV turning processes with different RVA: (a) cutting force signals and (b) Fast Fourier transform (FFT) spectra

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Fig. 9

Experimental comparisons from SSV turning processes with different RVF: (a) cutting force signals and (b) FFT spectra

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Fig. 10

Experimental performance of the proposed chatter suppression system in test 1: (a) cutting force signal, (b) experimental signals during the transition from with control to without control, (c) experimental signals during the transition from without control to with control, and (d) machined surface of the disk

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Fig. 11

Experimental performance of the proposed chatter suppression system in test 2: (a) cutting force signal, (b) experimental signals at the stable stage, (c) experimental signals at the chatter stage, and (d) machined surface of the disk

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