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In-Process Frequency Response Function Measurement for Robotic Milling
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In-Process Frequency Response Function Measurement for Robotic Milling
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Journal Article
In-Process Frequency Response Function Measurement for Robotic Milling
2023
Overview
Measuring the Frequency Response Functions (FRF) at the tool-tip is essential for the identification of chatter-free machining conditions. The tool-tip FRF in CNC machines are usually measured by impulse hammer tests in idle conditions, and the measured FRF remain relatively unchanged under operational conditions. This method is not effective in robotic machining, because the robot’s vibration response in idle and operational conditions are significantly different. The robot’s vibration response is pose-dependent and nonlinear and therefore strongly dependent on the operational conditions. This paper presents new methods for measuring the TCP (tool-tip) FRF of machining robots under operational conditions. In-process FRF are measured by leveraging the milling forces as the excitation source, and two approaches are proposed to achieve broadband, uncorrelated, and sufficiently exciting forces: i) milling of porous materials to generate randomized cutting forces, and ii) milling of a homogeneous material with spindle speed sweep. In the latter approach, the periodic content of cutting forces is used for excitation while in the former approach excitation by the random content is considered. A table dynamometer is used to measure the excitation (milling) forces and accelerometers are used to measure the resulting vibrations. The measured in-process FRF are then used to develop the chatter stability lobes diagram of the process, which determine the chatter-free combinations of the cutting depth and spindle speed for milling. Chatter experiments are conducted to confirm that the stability diagrams are more accurate when the presented in-process FRF measurements are used instead of the FRF measured in idle conditions.
Publisher
Springer International Publishing,Springer Nature B.V
