Identification of milling chatter based on a novel frequency-domain search algorithm
Identification of milling chatter based on a novel frequency-domain search algorithm
复制标题
基于新型频域搜索算法的铣削颤振识别
DOI：
10.1007/s00170-020-05789-7
复制
发表时间：
2020-08-01
影响因子：
3.4
通讯作者：
Lei, Gao
中科院分区：
文献类型：
--
作者：
Chang, Liu;Xu, Weiwei;Lei, Gao
颤振是一种自激振动，它会导致加工表面质量和尺寸精度非常差，甚至对加工操作产生有害影响。一种简单、可靠且准确的颤振识别算法对于在颤振充分发展之前采取控制策略至关重要。本文提出了一种新颖的频域搜索（FDS）算法来识别铣削过程中的颤振。根据FDS算法提取了一种基于振动基频的识别特征，在特征提取之前不需要复杂的信号处理算法。与大多数现有的识别特征相比，所引入的特征不需要根据不同的加工条件设置阈值。同时，特征提取只需要少量数据即可保证识别的及时性。进行了锤击试验和具有各种切削参数的铣削实验，并利用实验中的力信号和振动信号来验证所提算法的有效性。结果表明，所提算法无论是使用力信号还是振动信号，都能准确识别铣削颤振，甚至能识别出加工初期的轻微颤振。此外，研究表明，主要颤振频率出现在主轴 - 刀具系统的固有频率附近，但并不完全等于其固有频率。发现颤振频率是由系统的固有特性和切削条件共同决定的。
Chatter is a kind of self-excited vibration, which will result in very poor quality and dimensional accuracy on the machined surface, even a harmful effect on machining operation. A simple, reliable, and accurate chatter identification algorithm is crucial for taking control strategy before it is fully developed. This paper proposes a novel frequency-domain search (FDS) algorithm to identify the chatter during milling. An identification feature based on vibration base frequency is extracted according to the FDS algorithm, where the complicated signal processing algorithms are not needed before feature extraction. Compared with most of the existing identification features, the introduced feature does not need to set thresholds according to different machining conditions. Meanwhile, the feature extraction only needs a small amount of data to guarantee the timeliness of identification. Hammer test and milling experiments with various cutting parameters are carried out, and both force signal and vibration signal in the experiments are utilized to validate the effectiveness of the proposed algorithm. The results show that the proposed algorithm can identify the milling chatter accurately, whether using force signal or vibration signal, even slight chatter in the initial machining stage can be identified. Furthermore, the research reveals that dominant chatter frequencies appear around the natural frequency of the spindle-tool system but do not exactly equal to its natural frequency. The chatter frequencies are found to be determined by the combination of natural characteristics of the system and cutting conditions.