Development of a Low Cost In-Process Chatter Suppression System in Milling Process

This paper presents a low cost system for on-line chatter suppression during milling process. A novel MEMS accelerometer is used to acquire the vibration signal resulting from milling process. A band-pass filter is used to remove the low frequency forced vibration signals and high frequency noise, and remain the bandwidth of self-excited vibration signals. A microcontroller is employed as the control unit of the chatter suppression system. The standard deviation of acceleration is calculated and compared to the chatter threshold value. Whenever the calculated standard deviation is larger than the chatter threshold value, the control unit will actively adjust the spindle speed by fuzzy incremental PI control scheme. No system identification of the machine tool structure is needed. Experiments show that the proposed system can rapidly suppress the chatter and improve the surface texture of the workpiece.

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