In-process impulse response of milling to identify stability properties by signal processing

• Published in: Journal of sound and vibration 2022-06, Vol.527, p.116849, Article 116849
• Main Authors: Kiss, Adam K., Hajdu, David, Bachrathy, Daniel, Stepan, Gabor, Dombovari, Zoltan
• Format: Article
• Language: English
• Subjects: Chatter; Chatter detection; Differential equations; Dynamic stability; Dynamical systems; Floquet multiplier; Impulse response; In-process impulse response; Laboratory tests; Milling; Milling (machining); Multipliers; Numerical analysis; Parameters; Signal processing; Stability; Stability analysis; Systems stability
• ISSN: 0022-460X; 1095-8568
• DOI: 10.1016/j.jsv.2022.116849

In this work we present a quantitative measurement-based method to describe the stability behaviour of a periodic dynamical system. In-process response for impulse during milling is analysed to provide operational stability prediction. The proposed method combines chatter detection techniques with the theory of time-periodic delay differential equations applied for general milling operations. Signal processing based on dynamic modal decomposition approach not only presents qualitative properties (like stability/instability) but also quantifies a measure of stability through the determination of the Floquet multipliers. The corresponding monodromy operator of the milling process is approximated from the measured system’s response during machining operation. By changing the technological parameters, the variation of the modulus of the Floquet multipliers can be monitored. The stability limit can precisely be interpolated with the unitary multiplier; furthermore, the stability limit can be extrapolated while the manufacturing parameters remain in the chatter-free region. The presented approach is validated by numerical results and laboratory tests. •Measurement-based method to quantify stability of milling operation.•In-process impulse response is analysed to provide operational stability prediction.•It combines chatter detection techniques with the theory of time-periodic systems.•Extrapolation of stability limit opens ways for efficient cutting parameter optimization.•Results are supported by theoretical, numerical and experimental parts.