1 Introduction
2 Digital twin for process monitoring and control: a concept
3 Chatter methodology
4 Results
Cutting tool | Applied spindle speed (rpm) | Applied feed rate (μm/tooth) | Applied depth of cut (μm) | Cutting edge radius (μm) | Rake angle (°) | FFT analysis chatter? | Model prediction chatter? | Predicted stable depth of cut (μm) |
---|---|---|---|---|---|---|---|---|
A | 40,000 | 4 | 70 | 1.2 | 0 | Yes | Yes | 17 |
A | 40,000 | 4 | 70 | 3.3 | 0 | Yes | Yes | 14 |
A | 40,000 | 4 | 70 | 5.6 | 0 | Yes | Yes | 19 |
A | 40,000 | 4 | 70 | 14.5 | 0 | Yes | Yes | 11 |
A | 40,000 | 4 | 70 | 23.6 | 0 | Yes | Yes | 15 |
A | 24,000 | 8 | 50 | 1.2 | 0 | Uncertain | Yes | 44 |
A | 24,000 | 8 | 50 | 3.0 | 0 | Yes | Yes | 34 |
A | 24,000 | 8 | 50 | 6.6 | 0 | Uncertain | Yes | 48 |
A | 24,000 | 8 | 50 | 11.1 | 0 | Yes | Yes | 44 |
A | 24,000 | 8 | 50 | 14.1 | 0 | Yes | Yes | 23 |
B | 5000 | 6 | 100 | 3.5 | 8 | No | No | 227 |
B | 5000 | 12 | 100 | 3.5 | 8 | No | No | 114 |
B | 25,000 | 6 | 100 | 3.5 | 8 | No | No | 196 |
B | 25,000 | 12 | 100 | 3.5 | 8 | No | No | 120 |
B | 25,000 | 24 | 100 | 3.5 | 8 | Yes | Yes | 76 |
B | 50,000 | 6 | 100 | 3.5 | 8 | No | No | 192 |
B | 50,000 | 12 | 100 | 3.5 | 8 | No | No | 128 |
B | 50,000 | 24 | 100 | 3.5 | 8 | No | No | 125 |
5 Conclusions
-
a new chatter model using measured micro-milling cutting forces was developed and validated using FFT analyses;
-
a digital twin concept for process monitoring and control was presented to illustrate how the new chatter model can enable its realisation;
-
the presented digital twin concept for process monitoring and control will be demonstrated on an industrial use case in a future research;
-
a comparative study between the proposed chatted model and existing chatter models will be conducted as a future research for better understanding their respective advantages and disadvantages.