Machining chatter prediction using a data learning model

Abstract

Machining processes, including turning, are a critical capability for discrete part production. One limitation to high material removal rates and reduced cost in these processes is chatter, or unstable spindle speed-chip width combinations that exhibit a self-excited vibration. In this paper, an artificial neural network (ANN)—a data learning model—is applied to model turning stability. The novel approach is to use a physics-based process model—the analytical stability limit—to generate a (synthetic) data set that trains the ANN. This enables the process physics to be combined with data learning in a hybrid approach. As anticipated, it is observed that the number and distribution of training points influences the ability of the ANN model to capture the smaller, more closely spaced lobes that occur at lower spindle speeds. Overall, the ANN is successful (>90% accuracy) at predicting the stability behavior after appropriate training.