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Mitigation of Milling Chatter at High-Speed

[+] Author Affiliations
Meng-Kun Liu, C. Steve Suh

Texas A&M University, College Station, TX

Paper No. IMECE2012-88080, pp. 695-699; 5 pages
doi:10.1115/IMECE2012-88080
From:
  • ASME 2012 International Mechanical Engineering Congress and Exposition
  • Volume 4: Dynamics, Control and Uncertainty, Parts A and B
  • Houston, Texas, USA, November 9–15, 2012
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-4520-2
  • Copyright © 2012 by ASME

abstract

A highly interrupted machining process, milling at high speed can be dynamically unstable and chattering with aberrational tool vibrations. While its associated response is still bounded in the time domain, however, milling could become unstably broadband and chaotic in the frequency domain, inadvertently causing poor tolerance, substandard surface finish and tool damage. Instantaneous frequency along with marginal spectrum is employed to investigate the route-to-chaos process of a nonlinear, time-delayed milling model. It is shown that marginal spectra are the tool of choice over Fourier spectra in identifying milling stability boundary. A novel discrete-wavelet-based adaptive controller is explored to stabilize the nonlinear response of the milling tool in the time and frequency domains simultaneously. As a powerful feature, an adaptive controller along with an adaptive filter effective for on-line system identification is implemented in the wavelet domain. By exerting proper mitigation schemes to both the time and frequency responses, the controller is demonstrated to effectively deny milling chatter and restore milling stability as a limit cycle of extremely low tool vibrations.

Copyright © 2012 by ASME
Topics: Chatter , Milling

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