Abstract
Monitoring and early detection of chatter are the key techniques to avoid the harmful effects caused by chatter in manufacturing process. The key for early chatter detection is to capture the feature signatures. A convenient and reliable technique is presented in this study to detect chatter in gear grinding process based on servo feed motor current and wavelet packet transform. Wavelet packet transform was used to monitor the energy change in the frequency domain and to identify the feature frequency band with respect to chatter, the result of which was confirmed by the impact hammer test. Standard deviation and energy ratio of the feature frequency band signal were chosen as the indexes of chatter monitoring. Combining these two chatter features, the state of the grinding process could be classified and chatter could be detected reliably in industrial application with proper thresholds. Acceleration signals of the machine tool were used as a reference to compare with the results from current signals. In every stage of the grinding process, the feature frequency band signals of current and vibration signal have shown very coincident variation trend. Both theoretical analysis and experimental results manifested the feasibility and efficiency of the proposed method.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Quintana G, Ciurana J (2011) Chatter in machining processes: a review. Int J Mach Tools Manuf 51(5):363–376
Kuljanic E, Sortino M, Totis G (2008) Multisensor approaches for chatter detection in milling. J Sound Vib 312(4–5):672–693. doi:10.1016/j.jsv.2007.11.006
Weingaertner WL, Schroeter RB, Polli ML, de Oliveira Gomes J (2006) Evaluation of high-speed end-milling dynamic stability through audio signal measurements. J Mater Process Technol 179(1–3):133–138. doi:10.1016/j.jmatprotec.2006.03.075
Jeong Y-H, Cho D-W (2002) Estimating cutting force from rotating and stationary feed motor currents on a milling machine. Int J Mach Tools Manuf 42(14):1559–1566. doi:10.1016/S0890-6955(02)00082-2
Kim GD, Chu CN (1999) Indirect cutting force measurement considering frictional behaviour in a machining centre using feed motor current. Int J Adv Manuf Technol 15(7):478–484. doi:10.1007/s001700050092
Oh YT, Kwon WT, Chu CN (2004) Drilling torque control using spindle motor current and its effect on tool wear. Int J Adv Manuf Technol 24(5):327–334. doi:10.1007/s00170-002-1490-0
Sevilla-Camacho PY, Herrera-Ruiz G, Robles-Ocampo JB, Jáuregui-Correa JC (2011) Tool breakage detection in CNC high-speed milling based in feed-motor current signals. Int J Adv Manuf Technol 53(9):1141–1148. doi:10.1007/s00170-010-2907-9
Hun Jeong Y, Min B-K, Cho D-W (2006) Estimation of machine tool feed drive inclination from current measurements and a mathematical model. Int J Mach Tools Manuf 46(12–13):1343–1349. doi:10.1016/j.ijmachtools.2005.10.015
Soliman E, Ismail F (1997) Chatter detection by monitoring spindle drive current. Int J Adv Manuf Technol 13(1):27–34
Liu H, Chen Q, Li B, Mao X, Mao K, Peng F (2011) On-line chatter detection using servo motor current signal in turning. Sci China Technol Sci 54(12):3119–3129
Lange JH, Abu-Zahra NH (2002) Tool chatter monitoring in turning operations using wavelet analysis of ultrasound waves. Int J Adv Manuf Technol 20(4):248–254. doi:10.1007/s001700200149
Wu Y, Du R (1996) Feature extraction and assessment using wavelet packets for monitoring of machining processes. Mech Syst Signal Process 10(1):29–53. doi:10.1006/mssp.1996.0003
Gonzalez-Brambila O, Rubio E, Jauregui JC, Herrera-Ruiz G (2006) Chattering detection in cylindrical grinding processes using the wavelet transform. Int J Mach Tools Manuf 46(15):1934–1938. doi:10.1016/j.ijmachtools.2006.01.021
Choi T, Shin YC (2003) On-line chatter detection using wavelet-based parameter estimation. Journal of Manufacturing Science and Engineering-transactions of The Asme 125 (1). doi:10.1115/1.1531113
Yao Z, Mei D, Chen Z (2010) On-line chatter detection and identification based on wavelet and support vector machine. J Mater Process Technol 210(5):713–719
Cao H, Lei Y, He Z (2013) Chatter identification in end milling process using wavelet packets and Hilbert–Huang transform. Int J Mach Tools Manuf 69(0):11–19. doi:10.1016/j.ijmachtools.2013.02.007
Insperger T, Stépán G, Bayly PV, Mann BP (2003) Multiple chatter frequencies in milling processes. J Sound Vib 262(2):333–345. doi:10.1016/S0022-460X(02)01131-8
Hashimoto F, Kanai A, Miyashita M, Okamura K (1984) Growing mechanism of chatter vibrations in grinding processes and chatter stabilization index of grinding wheel. CIRP Ann Manuf Technol 33(1):259–263. doi:10.1016/S0007-8506(07)61421-8
Inasaki I, Karpuschewski B, Lee HS (2001) Grinding chatter—origin and suppression. Cirp Annals-Manuf Technol 50(2):515–534
Altintas Y, Weck M (2004) Chatter stability of metal cutting and grinding. Cirp Annals Manuf Technol 53(2):619–642. doi:10.1016/S0007-8506(07)60032-8
Li H, Shin YC (2007) A study on chatter boundaries of cylindrical plunge grinding with process condition-dependent dynamics. Int J Mach Tools Manuf 47(10):1563–1572. doi:10.1016/j.ijmachtools.2006.11.009
Karpuschewski B, Wehmeier M, Inasaki I (2000) Grinding monitoring system based on power and acoustic emission sensors. CIRP Ann Manuf Technol 49(1):235–240. doi:10.1016/S0007-8506(07)62936-9
Govekar E, Baus A, Gradisek J, Klocke F, Grabec I (2002) A new method for chatter detection in grinding. Cirp Annals Manuf Technol 51(1):267–270. doi:10.1016/S0007-8506(07)61514-5
Gradiek J, Baus A, Govekar E, Klocke F, Grabec I (2003) Automatic chatter detection in grinding. Int J Mach Tools Manuf 43(14):1397–1403. doi:10.1016/S0890-6955(03)00184-6
Tansel IN, Li M, Demetgul M, Bickraj K, Kaya B, Ozcelik B (2012) Detecting chatter and estimating wear from the torque of end milling signals by using index based reasoner (IBR). Int J Adv Manuf Technol 58(1–4):109–118. doi:10.1007/s00170-010-2838-5
Altintas Y, Ko JH (2006) Chatter stability of plunge milling. CIRP Annals Manuf Technol 55(1):361–364. doi:10.1016/s0007-8506(07)60435-1
Karpuschewski B, Knoche HJ, Hipke M (2008) Gear finishing by abrasive processes. Cirp Annals Manuf Technol 57(2):621–640
Zhijian M, Shuzi, Y.,Hanmin,S. (1988) Early detection and online monitoring of machine tool chatter. Journal of Vibration Engineering 1 (3)
Wickerhauser MV (1991) Lectures on wavelet packet algorithms.
Mallat SG (1989) A theory for multiresolution signal decomposition: the wavelet representation. IEEE Trans Pattern Anal Mach Intell 11(7):674–693. doi:10.1109/34.192463
Zhengjia H, Jiyuan Z, Yibin H, Qingfeng M (1996) Wavelet transform and multiresolution signal decomposition for machinery monitoring and diagnosis. doi:10.1109/icit.1996.601690
Yang J, Park ST (2003) An anti-aliasing algorithm for discrete wavelet transform. Mech Syst Signal Process 17(5):945–954. doi:10.1006/mssp.2002.1524
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Liu, Y., Wang, X., Lin, J. et al. Early chatter detection in gear grinding process using servo feed motor current. Int J Adv Manuf Technol 83, 1801–1810 (2016). https://doi.org/10.1007/s00170-015-7687-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7687-9