Integrated in-process chatter monitoring and automatic suppression with adaptive pitch control in parallel turning

Abstract

Simultaneous processes such as parallel turning or milling offer great opportunities for more efficient manufacturing because of their higher material removal rates. To maximize their advantages, chatter suppression technologies for simultaneous processes must be developed. In this study, we constructed an automatic chatter suppression system with optimal pitch control for shared-surface parallel turning with rigid tools and a flexible workpiece, integrating in-process chatter monitoring based on the cutting force estimation. The pitch angle between two tools is tuned adaptively in a position control system in accordance with the chatter frequency at a certain spindle speed, in a similar manner as the design methodology for variable-pitch cutters. The cutting force is estimated without using an additional external sensor by employing a multi-encoder-based disturbance observer. In addition, the chatter frequency is measured during the process by performing a low-computational-load spectrum analysis at a certain frequency range, which makes it possible to calculate the power spectrum density in the control system of the machine tool. Thus, the constructed system for automatic chatter suppression does not require any additional equipment.