Online milling chatter suppression based on open architecture controller

To realize online milling chatter suppression, general sensor monitoring technologies are investigated in the field of chatter monitor. The time domain and frequency domain sensitive signals are studied including each component in three-component cutting force and acceleration sensors by experiment. Aimed at the monitored chatter sensitive signal frequency characteristics, the techniques about the online extraction of effective information are studied with fast Fourier transform technique. The relationship model is set up between chatter frequency and spindle speed on the basis of the analysis of self-excited vibration mechanism, which provides the theoretical foundation to realize self-excited vibration suppression with variable spindle speed. A software type modular milling controller is designed integrated on the functions of online parameters acquisition and feedback control. Relative variable spindle speed algorithm to suppress the chatter is embedded in the open architecture controller, and the realization flowcharts for the control parameters data flow are also designed among the controller modules. On-line chatter suppression experiments are completed with continuous variable cutting depth aluminum alloy work-piece, and the experiments verify the correctness of the related technologies about on-line chatter suppression in the open architecture intelligent milling controller.