Abstract
In the paper, the problem of chatter vibration detection in the milling process of carbon fiber-reinforced plastic is investigated. Chatter analysis may be considered theoretically based on data from impact test of an end mill cutter. However, a stability region obtained in such way may not agree with the real one. Therefore, this paper presents a method that can predict chatter vibrations based on cutting force components measurements. At the beginning, a stability lobe diagram is created to establish the range of experimental test in the plane of tool rotational speed and depth of cut. Next, an experiment of composite milling is performed. The experimentally-measured time series of cutting forces are decomposed with the use of the improved Hilbert–Huang transform (HHT). To detect chatter, statistical methods and recurrence quantification analysis (RQA) are used. However, much better results are obtained when new chatter indexes are proposed. The indexes, derived directly from the HHT and RQA methods, can be used to build an effective chatter prediction system.
Highlights
Carbon fiber-reinforced composites (CFRC) are becoming more and more popular every year, year-round, as a material for the production of responsible machine parts in many industries such as aerospace, marine and automotive
Due to the difficulties and limitations mentioned above many works concentrates on the development of methods that could detect the initial symptoms of chatter, based on measurements of different signals, i.e., force, vibrations or acoustic emission [14,19,33,34]
The analyses presented were undertaken to verify whether the theoretical stability measured signals useful in chatter vibrations prediction
Summary
Carbon fiber-reinforced composites (CFRC) are becoming more and more popular every year, year-round, as a material for the production of responsible machine parts in many industries such as aerospace, marine and automotive. The products can be made in complex shapes, they need some machining, e.g., milling process, to achieve final dimensional and assembly requirements The features of these materials that make them a perfect choice in a variety of demanding applications, generate, many difficulties in their machining and choosing the right cutting tool. A comprehensive review of problems with tool wear and final product quality, related to machining of composite materials, are presented in [15,16,17,18]. Due to the difficulties and limitations mentioned above many works concentrates on the development of methods that could detect the initial symptoms of chatter, based on measurements of different signals, i.e., force, vibrations or acoustic emission [14,19,33,34] These signals are analyzed with the use of various signal processing techniques in time, frequency and time–frequency domains. Some remarks regarding the real area of stable machining conditions are presented in Section 5, practical conclusions and propositions of future research are presented
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