Chatter stability prediction and detection during high-speed robotic milling process based on acoustic emission technique
Chatter stability prediction and detection during high-speed robotic milling process based on acoustic emission technique
复制标题
基于声发射技术的高速机器人铣削过程中颤振稳定性预测与检测
DOI：
10.1007/s00170-021-07844-3
复制
发表时间：
2021-08-09
影响因子：
3.4
通讯作者：
Yang, Xujing
中科院分区：
文献类型：
--
作者：
Li, Maojun;Huang, Dingxiao;Yang, Xujing
颤振是机器人铣削加工中常见而棘手的问题，容易导致加工过程不稳定、刀具磨损严重、表面光洁度差。本文采用声发射技术，利用均方根值和快速傅立叶变换方法分析了机器人高速铣削铝合金时的颤振现象。提出了一种稳定波瓣图来预测不同主轴转速下的颤振发生，该图被认为是最有效的颤振分析工具。文中还给出了颤振稳定性的基本机理和理论分析，以提供对颤振稳定性的物理理解。首先建立了切削力模型和机器人结构模型，研究了其颤振机理。然后用零阶逼近法分析了机器人铣削系统的稳定性。结果表明，快速傅立叶变换和声发射信号的时域均方根值可以有效地用于检测和验证机器人铣削过程中的颤振。稳定波瓣图上的稳定切削区与实验结果相吻合，这有助于选择合理的切削参数，避免颤振，提高机器人高速铣削加工效率。
Chatter as a common and thorny problem occurs easily during robotic milling process, leading to the instability, severe tool wear and poor surface finish. In this work, an acoustic emission technique was employed to analyze a chatter phenomenon using root mean square (RMS) value and fast Fourier transform method during high-speed robotic milling of aluminum alloys (with cutting speed up to 678 m/min). A stability lobe diagram was proposed to predict the occurrence of chatter with various spindle speeds, which was considered as the most effective tool for chatter analysis. The underline mechanism and theoretical analysis were also presented to provide physical understanding of chatter stability. The cutting force model and robot structure model were firstly established to study chatter mechanism. The stability of a robotic milling system was then analyzed using a zero-order approximation method. Results showed that fast Fourier transform and the time-domain root mean square (RMS) value of acoustic emission signals could be effectively used for detection and verification of chatter in the robotic milling process. The stable cutting zone in the stability lobe diagram was in agreement with experimental results, which can help for the selection of reasonable cutting parameters to avoid chatter and improve efficiency during the high-speed robotic milling process.