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

2019 ◽  
Vol 142 (2) ◽  
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.

Spindle Speed Variation for Regenerative Chatter Suppression in Turning Process With Tool Wear Effect

2010 ◽  
Author(s):  
Kambiz Haji Hajikolaei ◽  
Masoud Rahaeifard ◽  
Gholamreza Vossoughi ◽  
Mohammadreza Movahhedy
Keyword(s):  
Tool Wear ◽  
Removal Rate ◽  
Spindle Speed ◽  
Turning Process ◽  
Machining Processes ◽  
Chatter Suppression ◽  
Spindle Speed Variation ◽  
Set Up ◽  
The Stability ◽  
Delay Differential

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the controller effect for two distinct cases of one and three sinusoidal speed are presented and compared.

The Effect of Spindle Speed Variation on Chatter Suppression in Rotating-Tool Machining

2006 ◽  
Vol 505-507 ◽  
pp. 859-864 ◽  
Author(s):  
Chen Jung Li ◽  
A.G. Ulsoy ◽  
W.J. Endres
Keyword(s):  
Spindle Speed ◽  
System Stability ◽  
Constant Delay ◽  
Machining Processes ◽  
Speed Variation ◽  
Chatter Suppression ◽  
Spindle Speed Variation ◽  
Common Process ◽  
The Stability ◽  
Stability Limits

Spindle speed variation (SSV) is one of a number of promising strategies to suppress chatter. Most previous research on SSV stability analysis for nonintermittent machining processes has focused on stationary-bar boring or turning. However, nonintermittent rotating-tool machining is also a common process. This paper investigates the effect of SSV in nonintermittent rotating-tool machining, using rotating-bar boring as an example. This paper takes advantage of the rotating-frame approach and the resulting constant delay in the angle domain to investigate the SSV effect on system stability for rotating-bar boring. The results show that the SSV effect on rotating-bar boring flattens the stability lobes and lifts the tangential stability limits.

Simulation and Experimental Research on Chatter Suppression Using Chaotic Spindle Speed Variation

2011 ◽  
Vol 133 (1) ◽  
Author(s):  
Kong Fansen ◽  
Liu Peng ◽  
Zhao Xingang
Keyword(s):  
Experimental Methods ◽  
Chaotic Signal ◽  
Spindle Speed ◽  
Speed Variation ◽  
Chatter Suppression ◽  
Spindle Speed Variation ◽  
Cutting Chatter ◽  
Chatter Control ◽  
Suppression Process ◽  
Chaotic Codes

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.

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

2018 ◽  
Vol 140 (12) ◽  
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.

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

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.

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

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.

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

2002 ◽  
Vol 124 (2) ◽  
pp. 208-216 ◽  
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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