Adaptive milling chatter identification based on sparse dictionary considering noise estimation and critical bandwidth analysis

Abstract

As one of the most unfavorable factors, chatter will seriously hinder the improvement of production efficiency. The weak chatter identification is an effective method for stable cutting. In this paper, a weak chatter identification method is developed using sparse dictionary on account of the milling dynamic responses. As the bases for chatter identification, chatter frequencies are calculated based on the milling dynamic equations. In order to decrease false alarm rate due to the measured background noise, the noise estimation based filtering is proposed. Besides, in consideration of the parameter uncertainty, an adaptive critical bandwidth analysis is implemented with the developed energy proportion index in case of missed alarm. Then, the sparse dictionary matrix is constructed based on the obtained chatter frequencies and critical bandwidth. Finally, the gradient projection for sparse reconstruction (GPSR) algorithm is adopted for chatter frequencies extraction. The proposed method can decrease the measured background noise, obtain critical chatter band and extract weak chatter frequencies accurately. Experimental results shows that the developed method can be successful in weak chatter identification.