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Prediction of Multiple Dominant Chatter Frequencies in Milling Processes
Abstract
Chatter frequencies of milling operations and their strengths are analyzed using the semi-discretization
method. It is known that milling processes, being parametrically excited systems, are theoretically associ-
ated with infinitely many chatter frequencies that are given as a base frequency plus an integer multiplier of
the tooth passing frequency (or the characteristic frequency of the cutter) according to the Floquet theory
[1]. The dominant vibration frequencies that are usually associated with chatter frequencies are however
hidden among the infinitely many harmonics. In this paper, it is shown that the amplitudes corresponding
to the individual frequency harmonics can be determined in a simple way by analyzing the eigenvectors of
the Floquet transition matrix obtained by the semi-discretization method without increasing the computa-
tional cost. The method can be used to determine the dominant frequency components that helps in the
identification of the interactions between different modes and the spindle speed.
Keywords: high speed machining, regenerative effect, delay differential equation, self-excited frequencies,
semi-discretization, chatter
Preprint submitted to International Journal of Machine Tools and Manufacture February 4, 2011
frequency domain, such as the single-frequency (SF) the following form
[5] and the multiple-frequency (MF) [6, 7] solutions, 2
while the semi-discretization (SD) [8] and the time- q(t) + [2l n,l ]q(t) + [n,l ]q(t)
finite element [9] are methods based on time domain. (1)
For completeness, there are continuation software = Ut F(t, q(t), q(t j )), j = 1, . . . , N ,
packages for general anholonome delay-differential 2
where [2l n,l ] and [n,l ] are (n n) diagonal ma-
equations (DDE), e.g. PDDE-CONT [10], which
trices with l and n,l being the damping ratio and
are capable to perform both linear and nonlinear
the natural angular frequency of the lth mode (l =
analysis of certain delayed systems. Generally, the
1, . . . , n). Due to the regenerative effect, the resul-
methods based on frequency domain can provide the
tant cutting force F depends on the current modal
dominant vibration frequency, but they can not han-
coordinate vector q(t) and N previous ones q(t
dle general milling processes (e.g. serrated cutters
j ), where N is the number of regenerative delays
[11, 12, 13]) and the rigorous linearization of nonlin-
occurring in the system. Note that F already con-
ear milling models.
tains the cutting force contributions of all flutes.
As opposed to turning processes, milling opera-
This general representation of the milling operation
tions are theoretically associated with infinitely many
self-excited frequencies (chatter frequencies) accord-
ing to the Floquet theory of DDEs [14] as it was
shown in [1]. However, the identification of the dom-
inant frequencies is not trivial. The frequency do-
main methods, the SF and the MF solutions, can
provide the strengths of the harmonics, although
these methods were mostly used to plot the domi-
nant frequencies only. In this paper it is shown that
the SD method is also able to derive the strengths of
the multiple chatter frequencies in an efficient way.
Moreover, the presented method can give the spec-
tra of the just developing self-excited vibration for
more complex milling models implemented in time
domain.
In the first part of the paper we show the con-
nection between the Floquet theory and the domi-
nant vibration frequency using rigorous mathemat- Figure 1: Schematic model of milling process with general
ical derivation. The method is based on the gen- modes.
eral representation of milling processes and it has
no significant effect on the computation time of the describes multiple delay cases that typically occur
SD method. In the second part of the paper we for non-uniform pitch angle tool [16] or for serrated
present a case study using the example from [15]. tools [11, 13] in contrast with the conventional mod-
Through this example one can realize how the self- els with a single delay being equal to the tooth pass-
excited frequencies can interact with other modes in ing period. In (1), the force is distributed to the
the system. A simple but useful frequency plot is modal directions by the mass normalized modal ma-
introduced here to understand the relationship be- trix
tween the self-excited frequencies and the dynamics
of the machine. In the last section, the theoretical U = Pdiag(cl ), where P = [P1 P2 . . . Pn ],
results are verified by experimental tests.
Pl is the modeshape vector and cl = (P|l Pl ml )1/2
is the normalization parameter of the lth mode, where
2. Milling Model ml is the modal mass corresponding to Pl . Since,
the tool is rotating, (1) is time-periodic at period
The relative vibration of the tool-tip is described T , which is the tooth passing period or an integer
in modal space defined by the modal coordinates divisor of the rotation period depending on the type
q = col(q1 , q2 , . . . , qn ) (see figure 1). The modes are of the cutter. The solution can be rewritten as the
supposed to be real, that is, the damping is propor- sum of a stationary and the perturbed motion, thus
tional, consequently, the equations of motion have
q(t) = qp (t) + u(t), qp (t) = qp (t + T ). (2)
Zoltan Dombovari CND-88-8888 2
The linear variational system of (1) can be deter- maps the initial state y0 () to yT (), the corre-
mined in the form sponding monodromy operator is U (T ). The solu-
2
tion after one period is given by
u(t) + [2l n,l ]u(t) + ([n,l ] + H(t))u(t)
PN yT () = (U (T )y0 )(). (6)
= j=1 Hj (t)u(t j ),
Moreover, the Floquet theorem also claims that a
where the coefficient matrices are general solution at the present time can be written
N
as a product of a time-periodic and an exponential
F X term in the form
Hj (t) = (t, qp (t), qp (tj )), H(t) = Hj (t).
q(t j ) j=1
yt (0) = y(t) = a(t)et , (7)
(3)
Note that these matrices are also time-periodic at where a(t) = a(t + T ) and the complex number
T , that is, Hj (t) = Hj (t + T ). Consider that, if is called characteristic exponent. In this manner,
(1) is linear, then Hj (t) is equal to the coefficient of an element of the function space at the period T is
q(t j ) in F and the costly calculation of qp by given by
the boundary value problem defined by (2) and (1)
is not necessary. Finally, the dynamic model can be yT () = y(T + ) = a()eT e , (8)
prepared for linear stability analysis in its first order
representation [17] as If one substitutes (8) into (6) an infinite dimensional
eigenvalue problem can be formulated as
N
X
y(t) = L(t)y(t) + Rj (t)y(t j ), (4) ((U (T ) I)s)() = 0, (9)
j=1
where I is an identity operator, the nonzero complex
where L(t) = L(t + T ) and Rj (t) = Rj (t + T )s are eigenvalue = eT is called characteristic multiplier
the linear and the retarded time-periodic matrices and, according to (8), the complex eigenvector has
and the new coordinates are defined as the form
u(t)
s() = a()e (10)
y(t) = . (5)
u(t) Note that s() is defined over the interval [max , 0].
Then, equation (9) has a nontrivial solution if
The stability of (4) can now be analyzed using the
SD method. ker{U (T ) I} =
6 {0}.
zi+1 = Bi zi , (12) Equation (14) shows that all of the terms will die out
except the critical one(s) if p is sufficiently large,
where zi = col(yi , yi1 , . . . , yir ) with r = int(max /+since all the other characteristic multipliers are in
1/2). Matrix Bi is actually the discrete represen- modulus less than one, i.e.,
tation of the solution operator U (t) over the time
interval t [ti , ti+1 ]. Multiple application of (12) ypT () bc pc sc () + bc pc sc ().
results in
Consequently, the critical characteristic exponents
zi+k = zi = Bi+k1 Bi+k2 . . . Bi+1 Bi zi , in (7) corresponding to the critical characteristic mul-
where the transition matrix is a finite dimensional tipliers can be derived using complex logarithm, that
discrete approximation of the infinite dimensional is,
monodromy operator U (T ). The (finitely many) ln|c | + i(argc + 2q) = c,q T,
eigenvalues of the transition matrix are close to the where c,q = c +ic,q (q can be any integer number)
multipliers of the monodromy operator depending and the multiple frequencies can be expressed as
on the step size U (T ) of the discretization. This ex-
plains why the stability diagrams constructed by the c,q = |c,b + q|, where = 2/T. (15)
SD method reliably approximates the exact stabil-
ity boundaries. The discrete representation of the Here c,b := c,0 = (argc )/T is the base frequency
eigenvalue problem (9) can now be formulated as that can be calculated directly from the critical mul-
tiplier and it indicates the lowest possible vibration
( I)S = 0, (13)
frequency, which satisfies the linear map (6) formu-
where I is a unit matrix and S is the discrete ap- lated by the Floquet theorem, i.e., T c,b [, ].
proximation of the eigenvector s() defined at (10). Equation (15) implies that infinitely many vibra-
If |m | < 1 for all m, then the system is predicted tion frequencies arise in the spectrum. These fre-
to be asymptotically stable. quencies are separated by the principle frequency
Zoltan Dombovari CND-88-8888 4
as it was shown in [1] and also coincides with [6]. The elements of the discretized critical eigenvector
Note that along the stability boundaries, the critical in (19) contain parts associated with modal displace-
asymptotic part c is zero, but in practice during ment and velocity as Sc,i = col(Sc,i , Wc,i ), similarly
the preparation of a stability chart the calculated in (17). The discrete counterpart of the periodic
points are never lying exactly on the border. Thus, terms can be defined based on (16) in the form
for the further investigations c = (ln|c |)/T should
Sc,i ec,b 0
also be considered. Using the SD method at a point Ac,i
Ac,i1 Sc,i1 ec,b
in the vicinity of the stability border, the approx-
Ac = = , (20)
imated spectrum of the monodromy operator can .. ..
. .
be calculated and the critical multiplier c and the Ac,ir Sc,ir ec,b r
discretized version of the corresponding eigenvector
Sc can be determined numerically (see (13)). The where again Ac,i = col(Ac,i , Vc,i ) as in (17). Note
definition of the eigenvectors at (10) gives the pos- that, the parts corresponding to the modal displace-
sibility to construct the time-periodic term of the ment and velocities are vectors defined based on the
critical eigenvector and to write it in Fourier series modal directions q in the form
form
Ac,k,q1 Vc,k,q1
X Ac,k,q2 Vc,k,q2
ac () = sc ()ec,b = ac,q eiq (16)
Ac,k = and Vc,k = ,
q=
.. ..
. .
where c,b = c + ic,b . Consider that, any c,q can Ac,k,qn Vc,k,qn
be substituted instead of c,b in (16), since ec,q T =
c , but that might cause numerical and indexing where k = i, i1, . . . , ir. The vector Ac is periodic
difficulties in the later analysis. In order to ob- and has the form on which low resolution Discrete
tain the dominant vibration level, the velocity of Fourier Transform (DFT) or Fast Fourier Transform
the vibration should be considered. According to (5) (FFT) can be applied in each modal directions. De-
the Fourier coefficient vectors can be decomposed to pending on the resolution of the discretization de-
parts corresponding to the modal displacement and scribed at (12), finite many approximations of the
velocities as Fourier coefficients ac,q can be determined in this
manner.
ac,q = col(ac,q , vc,q ). (17) During the construction of the transition matrix
In this way, the dominant vibration frequency is as- some irrelevant directions can be omitted in order
sociated with the maximum (highest infinite norm) to speed up the sometimes costly calculation [24, 17].
of the calculated Fourier coefficients of the vibration Basically, in milling the ignored directions are the
velocity. An implicit formula for the dominant fre- past modal velocities u(t + ), where [max , 0),
quency ratio qd can be given as since these do not influence the dynamics. There-
fore vc,q from (17) cannot be determined directly
vc,max = vc,qd = max ||vc,q || . (18) by DFT or FFT from Ac , instead one can calculate
q=
the approximate Fourier coefficients of the vibration
Note that any eigenvectors s() and any of their levels as vc,q = ic,q ac,q .
periodic terms a() are defined in the interval The dominant frequency ratio qd can be deter-
[max , 0]. This may cause representation problem mined from the resultant approximate Fourier coef-
of a(), since the condition max = T does not hold ficients vc,q applying (18). Consequently, the domi-
in all cases, e.g. for uneven pitch cutters [16]. In nant vibration frequency is given by
this case, mathematically, only the truncated ver-
sions of the eigenvectors are available, which means, c,d := c,qd = |c,b + qd |, (21)
their periodic terms cannot be restored in the en-
according to (15).
tire period. In order to overcome this issue, the in-
The major advantage of the above elucidated
terpretation of the state yt () should be given over
method is that it does not have a noticeable effect
an extended interval [T, 0] corresponding to
on the speed of the SD technique. Since the size
the principal period T of the milling process.
of the window equals to the principle period T , the
Using the SD method, only the discrete represen-
DFT or the FFT provides spectrum with the res-
tation of the critical eigenvectors can be determined
olution of the principle frequency = 2/T [25].
in the following form
Consequently, the discrete peaks actually coincide
Sc = col(Sc,i , Sc,i1 , . . . , Sc,ir ). (19) with original peaks ac,q , which are distributed also
Zoltan Dombovari CND-88-8888 5
by the principle frequency due to its definition in plot in figure 2a the dominant vibration frequen-
(16). In this way the dominant frequencies can be cies are indicated by black color along the stability
calculated efficiently along the stability limits and an boundaries. The strengths of the other harmonics
additional frequency plot can be provided above the were indicated by grayscale except the peaks that
stability diagram. One can plot the harmonics of the are less than 20% compared to the strength of the
dominant vibration frequencies and represent their dominant frequency. Certain resonant frequencies
weights based on their amplitudes. This frequency l = n,l /N of the modes are pointed out in figure
plot may help to identify the source of certain vibra- 2 referring to the resonant spindle speeds, the flip re-
tions occurring during machining. gions and the mode interaction zones [26]. In figure
2a one can follow that the dominant vibration fre-
quencies are in most of the cases close to the natural
6. Case Study
frequencies. Point D corresponds to period doubling
(flip) bifurcation that can be recognized in figure 2a
as the frequencies are lying on the lines that are odd
multiples of a straight line with slope 1/2 [27]. Point
B and D represent simple cases, when only the dom-
inant frequency is strong. For points A and C some
other harmonics also show up besides the dominant
one. The relevant multipliers with the unit circle are
depicted in figure 2b and the type of the stability loss
can be associated in this way at points (A, B, C, D).
7. Experimental Verification
1480, 1600, 1750, 2000, 2400, 2600, 3000 rpm. The
The presented method to predict the dominant maximum axial depths of cut were kept to be 4 mm
vibration frequencies was verified experimentally. In for safety reasons except the measurements A and
this section, we give an overview of the measurement H that were both stable all along the shots (cf. fig-
and the results of the tests performed using conven- ure 6). One can directly realize by means of the
tional milling operation. measurement-sketch in figure 5d that the cutting
process jumped to chatter at higher axial depths of
7.1. Measurement Environment cut than it restored to stationary cutting. This can
A measurement setup shown in figure 4 was cre- be explained by the so-called unsafe zones, which
ated to have a clear and flexible mode perpendic- are the effect of the nonlinearities occurring in the
ular to the feed direction (x). Four modes (one in cutting force characteristics [29, 30, 31].
the (x) and three in the (y) directions) and the cor-
responding modal parameters are given in table 2.
A continuous variation of the axial depth of cut ap
was achieved by using a ramp-like (or roof-like) mir-
ror slope on steel (C45) workpiece with 5 mm high-
est axial depth of cut in the middle (see figure 5d).
This strategy can lead to a more accurate and also
quicker determination of the practical limit of the
stability than the often used step-cutting strategy.
However, the identification of the accurate depth of
cut is not clear. Here, the average depths of cut of
the individual teeth were considered, which yields
Figure 4: shows the measurement arrangement used for chat-
to a shift (D/) of the effective position compared ter tests.
to the center of the tool (thin vertical line in fig-
ure 5d). The tool was a four fluted N = 4 in-
serted cutter with helix angle 20 deg and di- 7.2. Evaluation of the Results
ameter D = 32 mm. Because of the limited width
of the workpiece near full-immersion milling was per- The limit depths of cut were calculated indirectly
formed successively side by side with 31 mm radial from the measured motion of the tool s using the
immersion. This causes 20.36 deg deviation in the actual time when the tool entered into the slope,
entry angle en (see figure 1) compared to the per- the time when it lost its stability and the feed f =
fect arrangement. Preliminary tests were performed 0.8 mm/rev. The instant of entrance into the work-
to identify the cutting coefficients of the linear cut- piece can be obtained directly from the time domain
ting force model [28]. The tangential and the ra- representation of the signals (figure 5c). But, in or-
2 der to have the instant of stability loss, the strength
dial cutting coefficients were Kt = 1459 N/mm and
2 of the just-developing-frequency of the self-excited
Kr = 259 N/mm , respectively.
vibration (in practice the so-called chatter frequency,
During the measurements accelerations were col-
C ) needs to be compared with the strongest peak of
lected by a data acquisition system in the feed direc-
the forced vibration (usually the peak of the tooth
tion (x) and the direction perpendicular to the feed
passing frequency, T ) related to the same direc-
(y). Eight different speeds were selected and six of
tion. For this purpose, short-time Fourier transform
those are shown in figure 5c, where black and grey
(STFT) was applied on the time signals using slid-
colours correspond to the (y) and (x) directions, re-
ing Hann window of length 1 s with time-step 0.1 s
spectively. The selected speeds were: nA,B,C,D,E,F,G,H =1420,
and the spectra were transformed to vibration level
|FFT(v(t))| in frequency domain. The process was modes have effect on the stability since the dom-
declared to be unstable when the peaks of the self- inant frequencies lay close to the first three nat-
excitation and the corresponding forced vibration ural frequencies n,1...3 . On the other hand some
were roughly equal and the position of the moving harmonics of the self-excited frequencies are active
tool was determined at that time. Using this strat- (grey-scale), but in the region of the measurements
egy relatively large error on the tool-position s re- (n [1400, 3000] rpm) only small portions of them
sults in negligible error on the axial depth of cut due are significant. Note that this does not show up
to the gentle slope. On figure 5b the measured sta- in the prediction if one uses exact full-immersion
bility limits are indicated by crosses while the stable milling model during the calculations. In this case,
shots are by arrows with tips up to the reached max- the inside symmetry due to the full-immersion sense
imum depths of cut. Compared with the predicted and the approximated circular orbits of the flutes
stability limit (solid line) the trend of the large lobe make the periodical force smoother than it is in the
can be recognized. reality. Generally, the predicted frequencies agree
The predicted frequencies of the self-excited vi- well with the measured spectrum (chatter frequen-
brations and their harmonics are plotted in figure 5a cies and their harmonics) depicted by circles in fig-
by thick grey-scale, so that, the dominant vibration ure 5a. The size of the circles are proportional to
frequencies c,d (21) are black, while the weaker ones the measured peaks and the values next to the cir-
are grey proportional to their strengths. The thin cles show the strength of the predicted peaks (in
grey lines show the non-operating (with strengths percentage) compared with the strength of the dom-
less than 2.5%) multiple harmonics c,q (15) of the inant frequency.
dominant frequencies. The horizontal and the in- The critical STFT intervals, where the signs of
clined dashed black lines indicate the natural fre- the stability loss were first identified are denoted by
quencies n,1...4 (table 2) and the tooth passing fre- dashed lines in figure 5c. The FFTs of the signal
quencies T = N n/(60 s/min) and their harmon- over the critical intervals are presented in panels e)
ics. The lines M = T /2 and their harmonics, on for cases C, D, E and G. The continuous and dashed
which the frequencies of the double period (flip) self- guidelines in panels e) correspond to those in fig-
excited orbits can lay are marked by inclined grey ure 5a, while dotted lines denotes the harmonics
dashed lines [27]. of the spindle frequency n = n/(60 s/min). The
According to figure 5a two things can be real- grey and black lines indicate the spectra in direc-
ized directly. On one hand, only the first three tion of (y) and (x). In all samples, the peaks that
do not coincide with any harmonics of the spindle are taken from the critical intervals since the chatter
frequencies are the frequencies of the self-excited vi- peaks are about the level of the strongest forced fre-
brations (practically the chatter frequencies C ) or quency. Note that for case D, the strongest forced
their harmonics. One can realise that these samples frequency is in the feed direction (x), while chat-