Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring
Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring
复制标题
DOI：
10.1007/s12541-021-00469-2
复制
发表时间：
2021-01
影响因子：
1.9
通讯作者：
Shuntaro Yamato;K. Nakanishi;N. Suzuki;Y. Kakinuma
中科院分区：
文献类型：
--
作者：
Shuntaro Yamato;K. Nakanishi;N. Suzuki;Y. Kakinuma
为了最大限度地提高平行铣削等同步加工过程中的高材料去除率，开发成功抑制/避免颤振的策略是制造商关注的一个重要问题。在这项研究中，讨论了主轴速度差法(SDM)抑制颤振的有效性，在平行的端面加工过程中，柔性零件被两个相反方向旋转的刀具加工。考虑到再生效应引起的动态变化发生在与刀具轴线方向垂直的平面上，建立了工艺模型。通过过程模拟和实验，本研究为理解过程行为提供了有益的探讨。此外，通过将基于无传感器切削力估计的颤振监测系统与滑动离散傅立叶变换相结合，开发了一种自适应SDM实时主动颤振抑制系统，其中主轴速差在过程中根据跟踪的颤振频率进行顺序优化。结果表明，所开发的主轴转速实时自适应系统比非自适应SDM系统更有效地抑制了颤振，因此，该集成系统可以为面向工业4.0的自优化加工系统做出贡献。
To maximize the potential for high material removal rates in simultaneous processes such as parallel milling, developing strategies for successful chatter suppression/avoidance is an important concern for manufacturers. In this study, the effectiveness of the spindle speed difference method (SDM) for chatter suppression is discussed in a parallel end-milling process where a flexible workpiece is machined by two tools rotating in opposite direction. The process model is developed, considering that the dynamic variation due to the regenerative effect occurs on a plane perpendicular to the tool axis direction. Through the process simulations and the experiments, this study provides informative discussion for comprehending the process behavior. Additionally, a real-time active chatter suppression system with adaptive SDM, where the spindle speed difference is sequentially optimized during the process according to the tracked chatter frequency, is developed by integrating a chatter monitoring system based on sensorless cutting force estimation with sliding discrete Fourier transform. The results show that the developed real-time adaptive system of spindle speed suppresses chatter vibrations more effectively than non-adaptive SDM system; hence, the integrated system can contribute self-optimizing machining systems oriented to Industry 4.0.