Internal Energy Based Analysis on Mechanism of Spindle Speed Variation for Regenerative Chatter Control

Among machining chatter control methods, spindle speed variation (SSV) method is certified as a feasible and effective way: machining chatter can be suppressed by continuously and periodically fluctuating the spindle speed of the machine tool. Although with its substantial value, the SSV method has not yet gained enough acceptance in the industrial machining applications. One of the reasons is the inadequacy of theoretical and practical study on the mechanism of the SSV method for machining chatter suppression. In this paper the mechanism of the SSV method for chatter suppression is revealed by means of internal energy analysis. The theoretical analysis is based on a nonlinear delay differential equation (NLDDE) as the model of regenerative machining chatter. This approach can provide more practical and feasible analytical results than small perturbative approaches. The analytical results demonstrate the machining stability increment of SSV cutting in the mathematical and physical sense, and provide practical suggestions for selection of SSV cutting parameters. Numerical simulations and experimental SSV cutting testing outcomes have coincidence with the analytical results.

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