Nonlinear/Chaotic Analysis of Machining Data

Statement of Purpose
For The Degree of
Master of Science

Proposed by
Seyyed Reza Haqshenas
In view of the accelerating trends of innovation in machine design, in new technologies, new
electronic systems and in other branches of science, more complex approaches and more
exact solutions are required. This cannot be done without consideration of the very detailed
mathematical models respecting the nonlinear characteristics of the real physical systems.
The majority of systems occurring in nature have a nonlinear character. It means that a
change in the behavior of the system is not a simple function of the changes in initial
conditions. Chaotic behavior is a certain type of a nonlinear behavior characterized by a high
sensitivity to initial conditions.

Partial list of the physical systems known to exhibit chaotic vibrations includes the following
[1],[2]:

• Vibrations of buckled elastic structures

• Mechanical systems with play or backlash such as gears
• Systems with sliding friction
• Rotating or gyroscopic systems
• Nonlinear acoustic systems
• Large, three-dimensional vibrations of structures such as beams and shells
• Chaotic dynamic in manufacturing processes

These are but a few of the many phenomena which chaos has been uncovered. Here, I want to
emphasize on the last item. Manufacturing is the conversion of raw materials into desired end
products. One of the most important manufacturing process is Material removal process, that,
Geometry is generated by changing the mass of the incoming material in a controlled and
well-defined manner, e.g., milling, turning, electrodischarge machining, and polishing [3].
Dynamics of cutting process is nonlinear and very complex. The most influential works on
the dynamics of machine tools and cutting processes were conducted in the mid forties by
Merchant [4],[5], and later, in the 1950s and 1960s, by Russians. The study conducted by
Zorev is a good example of those investigations, where the dynamics characteristics of the
cutting process play a key role in process stability. Contrary to this approach, there is a
significant body of research assuming that the machine-tool structure is responsible for the
dynamic instabilities (e.g. Tlusty [6]).

Tool chatter described as a self-excited, large amplitude vibration of the tool, is a cutting
phenomenon which results in reduced surface quality of the manufactured workpiece,
increased tool wear, defected spindle, lower productivity rate. Because of its unfavorable
effects and frequent occurrence, tool chatter has been studied intensively, both analytically
and experimentally. Nonlinear properties of the cutting process and insufficient rigidity of the
machine-tool were found to be crucial for the emergence of chatter. Many models of tool
chatter have been proposed, but none of them has gained widespread acceptance leading to a
general chatter control strategy.

Recent investigations into nonlinear dynamics have shown an existence and importance of
chaotic motion occurring in machining. The models by Grabec [7], Wiercigroch [8] have
shown evidence of chaotic vibrations, which are mainly due to the nonlinearity of the dry
friction and the intermittent contact between the cutting tool and the workpiece. In the case of
lathe cutting, Hively[9], found that nonchatter cutting occur at low-spindle speeds with
multiple periodicities, low-acceleration amplitude, and strongly chaotic features. Chatter
occurred at higher spindle speeds with high-acceleration amplitude, low complexity, weak
chaotic features, and strong periodic dynamics.

Another cutting process shows chaotic feature is High Speed Milling which is crucial for
aerospace die/mold industry. It is a challenging task for researchers to explore its special
dynamical properties, including stability conditions of the cutting process and the nonlinear
vibrations which may occur near to the stability boundaries. These dynamical properties are
mainly related to the underlying regenerative effect in the same way as it is in case of the
classical turning process having complicated but well-studied and understood stability
properties. Still, some new phenomena (Like period doubling bifurcation, Hopf bifurcation)
appear for low-immersion milling as predicted by Davies [10],[11]. These phenomena were
also reported by Insperger and Stépán [12].[13].[14] in case of milling independently from
the immersion or speed characteristic of the milling processes.

According to above discussion, extreme significance of machining process (esp. High Speed
Machining (HSM)) and potentiality of this issue for more detail research, I'd like to continue
my researches and studies at Master degree program in the field of Nonlinear Dynamics and
control esp. dynamics of machining process which is strongly nonlinear. I want to investigate
different proposed models for HSM analytically and experimentally applying
Nonlinear/Chaotic Time series analysis [15],[16] of sensors signals (sensors like
accelerometers, force sensors, strain gauges, microphone) to extract dynamical and
vibrational features of process (preferably on-line). Thereby, we can utilize these data for
condition monitoring of cutting process or developing a control strategy which predicts
chatter and hinders its occurrence. About the control strategy, I think anti-chaos control
seems feasible. As I mentioned before, before chatter vibrations occur, system behaves
chaotically and it is sensible to keep it in chaotic situation to defy chatter.

Condition monitoring (or controlling) based upon sensor signal

Refrences
[1] Moon, F.C.," Chaotic and Fractal Dynamics", JOHN WILEY & SONS,Inc.

[2] Moon, F.C.," Dynamics and Chaos in Manufacturing Processes" ,JOHN WILEY &
SONS,Inc.

[3] Lee, J.; et. al. “Modern Manufacturing", from Mechanical Engineering Handbook Ed.
Frank Kreith, Boca Raton: CRC Press LLC, 1999

[4] Merchant, M.E.," Basic Mechanics in metal cutting process", ASME, J of Appl. Mech.,
1944

[5] Merchant, M.E.," Mechanics of metal cutting process", J of Appl. phys., 1945

[6] Tlusty, J. "Dynamics of high speed milling", J. of Engng Industry, 1986

[7] Grabec, I., "Chaotic dynamics of the cutting process", Int. J. Mach. Tools Manufact.
1988

[8] Wiercigroch, M., "Chaotic vibration of a simple model of the machine tool cutting
process system", ASME, J. of Vibration Acoustics, 1997

[9] Hively, L., "Nonlinear analysis of machining data", 1996

[10] Davies et al., "Stability prediction for low radial immersion milling", ASME, J of Manu.
Sci. and Engng. ,2002

[11] Davies et al., "Interrupted Machining – A Doubling in the Number of Stability Lobes?,
The J. of Manu. Sci. and Engng.

[12] Insperger, T., Stépan, G.," Regenerative vibration of milling process",

Proceed. of Dynamics and Control of Mech. Processing (Budapest), 1999

[13] Insperger T., Stépan G., "Stability of High-Speed Milling", Proceed. of

ASME Symp. on Nonlinear Dynamics and Stochastic Mechanics, 2000

[14] Insperger, T., Stépan, G., "Vibration Frequencies in high-speed milling processes", J of
Manu. Sci. and Engng. , 2000

[15] Hively et al. " Condition assessment of nonlinear processes", US Patent, 6 484
132,2002

[16] Hively et al. " Integrated method for chaotic time series analysis", US Patent, 5 815
413,1998