Chatter stability prediction for CNC machine tool in operating condition through operational modal analysis

• Published in: Mechanics & industry : an international journal on mechanical sciences and engineering applications 2016-01, Vol.17 (4), p.402
• Main Authors: Lamraoui, M., El Badaoui, M., Guilleti, F.
• Format: Article
• Language: English
• Subjects: Acceleration; Algorithms; Chatter; CPE; Cutting parameters; Cutting speed; Damping ratio; Dynamic characteristics; Dynamic stability; Editing; EMA; Estimation; Excitation; Frequency response functions; High speed machining; Impact tests; Least squares; LSCE; Machine tools; Mathematical analysis; Milling (machining); Modal analysis; modal parameters; OMA; Resonant frequencies; Signal processing; Spindles; Stability lobes; Static stability; Surface properties; White noise
• ISSN: 2257-7777; 2257-7750
• DOI: 10.1051/meca/2015038

The stability of high-speed machining operations is crucial in machining process and presents a key issue for insuring better surface quality, increasing productivity and protecting both machines and safe workpiece. Stability prediction in milling is based on experimental modal analysis by the estimation of frequency response functions using a tap test. One limitation of accurately estimating the stability using such approach is the change in process and the dynamic characteristics of the machine tool under operation. This paper proposes a signal processing procedure applied to vibrations in machining process in order to obtain spindle’s modal variations in operation. The novelty of the proposed approach consists in removing “virtual modes”, caused by harmonic excitations, from the system response before performing operational modal analysis. Thus, the proposed procedure combines two existing techniques that are the Cepstral Editing Procedure and the Least Square Complex Exponential. The importance of the developed methodology is in adjusting the chatter stability criterion for material removal on a dynamic basis. The main work is given as follows: first of all, the Cepstral Editing Procedure (CEP) algorithm is applied on the acceleration signals for removing deterministic vibrations caused by harmonic excitations. The residue signal is the system response to white noise excitation. The frequency response functions (FRF) are then calculated from these signals at different cutting conditions. The outcome is compared to the result of impact test on the spindle under static condition. Similarities in the form of FRFs obtained in static and operational conditions validate the proposed approach while variations of modal properties under different cutting conditions are successfully captured. Secondly, the Least Square Complex Exponential (LSCE) method in operational modal analysis is invoked to find the natural frequencies and damping ratios of the system at different spindle speeds and cutting depths. Then, the dynamic chatter stability lobes diagrams (SLD) are established which account for spindle’s speed-dependent modal variations. A significant change in the stability border is observed which is interesting in machining fields. It will be shown that some depths of cut that are stable with static stability lobes become unstable with dynamic stability lobes and vice versa.