Feasibility study of optical detection of chatter vibration during milling

This article introduces an optical device for measuring and recording the vibrations during milling. The constructed apparatus is able to discriminate between stable cutting and chatter vibration. A review of various chatter detection methods is presented. It lists basic numerical approximation methods to predict chatter and the devices used to detect unstable cutting. A discussion on the importance of experimental detection versus theoretical predictions is also included. The article further presents the measurement setup, its basic components, and their parameters along with the basic principles of the measurements and the theoretical framework of the stability analysis. The theoretical framework is then applied to show the chatter determining frequencies and to determine what has to be detected during the measurements. Experimental results for slotting and down milling with different immersion ratios are also presented. These include stability maps based on the power spectrum density (PSD) graphs of the collected data and confirmed by photographs of the cut surfaces. The conclusion summarizes the results, and describes advantages and disadvantages of the setup.