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Procedia CIRP 00 (2018) 000–000 www.elsevier.com/locate/procedia
Procedia
Procedia CIRP CIRP 00 (2018)
00 (2017)
Procedia CIRP 000–000
000–000
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8th CIRP Conference on High Performance Cutting (HPC 2018)

8th
8th CIRP
CIRP Conference
Conference on
on High
High Performance
Performance Cutting
Cutting (HPC
(HPC 2018)
2018)
High-speed
High-speed camera measurements in the mechanical analysis of machining
High-speed camera
camera measurements
measurements in
in the
the mechanical
mechanical analysis
analysis
28th CIRP Design Conference, May 2018, Nantes, France
of
of machining
machining
a,* a a
Szabolcs
Szabolcs Berezvai
Berezvai a,* , Daniel Bachrathya , Gabor Stepana
a,* , Daniel Bachrathya , Gabor Stepana
Szabolcs Berezvai , Daniel Bachrathy , Gabor Stepan
A new methodology toUniversity
analyze theand functional of and physical architecture of
a Budapest University of Technology and Economics, Faculty of Mechanical Engineering,
a
Budapest of Technology Economics, Faculty Mechanical Engineering,
Department
a
Budapest of Applied
University Mechanics,
of Technology Muegyetem
and rkp.
Economics, 5., Budapest
Faculty H-1111,
of Mechanical Hungary
Engineering,
Department of Applied Mechanics, Muegyetem rkp. 5., Budapest H-1111, Hungary
∗
∗
∗
existing products forfax:
Department
Corresponding author. Tel.: +36-1-463-1235;
Corresponding author. Tel.: +36-1-463-1235; an+36-1-463-1369.
fax: assembly
+36-1-463-1369. E-mailoriented
of Applied Mechanics, Muegyetem
E-mail
product family identification
rkp. 5., Budapest H-1111, Hungary
address: berezvai@mm.bme.hu
address: berezvai@mm.bme.hu
Corresponding author. Tel.: +36-1-463-1235; fax: +36-1-463-1369. E-mail address: berezvai@mm.bme.hu

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat

Abstract
Abstract
Abstract École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
In this paper, we present the application of high-speed camera recordings in the mechanical analysis of machining processes. The modelling of the
In this paper, we present the
workpiece-machine-tool application
mechanical of high-speed
system camera recordings
is a very complex in the mechanical
and challenging engineeringanalysis
problemof machining processes. Theatmodelling of the
In this paper, we present the application of high-speed camera recordings in the mechanical analysis ofhaving important
machining features
processes. multiple scales
The modelling of the
*workpiece-machine-tool
Corresponding
both in time author.
and in space.mechanical
Tel.: +33
The 3 87 37 system
54
observation 30; is aexperimental
E-mail
and very complex
address: and challenging
paul.stief@ensam.eu
analysis of such engineering
phenomena problem
are important having
in important
terms
workpiece-machine-tool mechanical system is a very complex and challenging engineering problem having important features at multiple scales of features and
developing at multiple scales
validating the
both in time and
corresponding in space. The
mechanical modelsobservation and experimental
and results. This paper is analysis
dedicatedof such phenomena our are importantregarding
in terms of developing and validating the
both in time and in space. The observation and experimental analysis oftosuch
summarize
phenomena experiences
are important in terms the optimal measurement
of developing set-up
and validating the
corresponding
and instrumentationmechanical models
of mechanical and results.
investigations This paper
using is dedicated
a commercial to summarize our experiences regarding the optimal measurement set-up
corresponding mechanical models and results. This paper is dedicated Photron FASTCAM
to summarize SA5 High-Speed
our experiences Camera
regarding System.
the optimal Furthermore,
measurement the
set-up
and instrumentation
applicability of mechanical
of high-speed investigations
camera recordings usingprovided
are also a commercial
via the Photron
detailed FASTCAM
case study ofSA5
shearHigh-Speed Cameraand
angle estimation System.
chatter Furthermore,
detection. the
and instrumentation of mechanical investigations using a commercial Photron FASTCAM SA5 High-Speed Camera System. Furthermore, the
Abstract
applicability of high-speed camera recordings are also provided via the detailed case study of shear angle estimation and chatter detection.
applicability of high-speed camera recordings are also provided via the detailed case study of shear angle estimation and chatter detection.
©
c 2018
2018 TheThe Authors.
Authors. Published
Published by by Elsevier
Elsevier Ltd.
Ltd.
c today’s
This2018
is anThe Authors.
open access Published
article by
under Elsevier
the Ltd.
In
Peer-review
c business
under environment,
the the
responsibility
 2018 The Authors. Published by Elsevier ofCC
trend theBY-NC-ND
towards morelicense
International
Ltd. product (https://creativecommons.org/licenses/by-nc-nd/4.0/)
variety
Scientific and customization
Committee of the 8thisCIRP
unbroken. Due to on
Conference thisHigh
development, the need
Performance of
Cutting
Selection
Peer-review
agile and peer-review
under the under
responsibilityresponsibility
(HPC 2018). under the responsibility of theemerged
and
Peer-review reconfigurable production of
systemsthe of thetoInternational
International
International
Scientific
cope Scientific
Committee
with various
Scientific
Committee
products
Committee
of and
the 8thofCIRP
the families.
product
of the 8th CIRP
8thConference
CIRPTo Conference
Conference
on High
design
on HighandonPerformance
High Performance
optimize Cutting
production
Performance Cutting
Cutting
(HPC
systems (HPC
2018).
as well2018).
as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to
(HPC 2018).
Keywords:
analyze a Cutting,
product Measuring
or one product instrument,
family on Optical, Chatter,level.
the physical Chip Different product families, however, may differ largely in terms of the number and
Keywords: Cutting, Measuring instrument, Optical, Chatter, Chip
Keywords:
nature of components. This fact impedes an efficient comparison
Cutting, Measuring instrument, Optical, Chatter, Chip and choice of appropriate product family combinations for the production
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster
these products in new assembly oriented product families for the optimization
1. Introduction theof limitations
existing assembly lines and the creation
of applicability using aofcommercial
future reconfigurable
Photron
1. Introduction
assembly systems.
1. Introduction Based on Datum Flow Chain, the physical structure of the
the limitations
products is
the limitations of
analyzed.applicability
Functional using a
subassemblies commercial Photron
are identified, and
FASTCAM SA5ofHigh-Speed
applicabilityCamera
using aSystem.
commercial Photron
Furthermore,
a functional analysis is performed. Moreover, a hybrid functional and physical FASTCAM architecture
SA5 graph (HyFPAG)
High-Speed is the output
Camera System. which depicts the
Furthermore,
The accuracy and performance of metal cutting processes FASTCAM
the applicabilitySA5 High-Speed
of high-speed Camera
camera System. Furthermore,
recordings are also
similarity between product families by of providing design support to both, theproduction system of
applicability planners and product
high-speed cameradesigners. An illustrative
are
The
The
often
accuracy
accuracy
limited
and
and
by
performance
performance
the occurrence of
of
metal
metal
harmful
cutting
cutting processes
processes
self-excited vi- the applicability
demonstrated via of high-speed
detailed case cameraofrecordings
studies recordings
the
are
are also
observation also
of
example
are oftenof limited
a nail-clipper
by is used
the to explain
occurrence of the proposed
harmful methodology.
self-excited vi- An demonstrated
industrial case study
via on two product
detailed case familiesof
studies of the
steering columns of
observation of
are often
brations
thyssenkrupp limited
called by
machine
Presta the
France is occurrence
tool
then chatter. ofDue
carried Due harmful
to its
out totogive self-excited
undesired vi-
con-
a first industrial demonstrated
shear
evaluation angle
of via
during
the proposed detailed
orthogonal case studies
cutting and of the
chatter observation
detection
approach. cutting and chatter detection dur- of
dur-
brations called machine tool chatter. its undesired con- shear
shear angle
angle during
during orthogonal
orthogonal cutting and chatter detection dur-
brations
sequences
©sequences called machine
including
2017 The Authors. poor
Publishedtool chatter.
surface Due
quality,
by Elsevier to its undesired
increased tool
B.V.increased tool wear con-
wear ing milling processes.
including poor surface quality, ing milling
ingDesign
milling processes.
processes.
sequences
and the damage
Peer-review including
under of thepoor
toolsurface
responsibility and quality,
scientificincreased
workpiece,
of the tool
of thewear
there is significant
committee 28th CIRP The outline of the2018.
Conference paper is the following: In Section 2, the
and the damage The
The outline of
of the paper is
is the following: In
In Section 2,
2, the
and
needthe damage of
to understand
the tool
of the tool and
and workpiece,
dynamics workpiece,
of cutting [1–4].
there
there is is significant
significant high-speed outline
camera the paperwith
system the following:
suggested Sectionparam-
measurement the
need to understand the dynamics of cutting [1–4]. high-speed
high-speed camera system with suggested measurement param-
need to modelling
Keywords:
The understand
Assembly; Design thethe
of dynamics
method; of cutting
Family [1–4]. mechanical
identification
workpiece-machine-tool eter range iscamera system
presented. Thewith
casesuggested
study of measurement param-
shear angle variation
The eter range is
is presented. The
The case study of
of shear angle
angle variation
The modelling
system modelling
during machining
of
of the
the workpiece-machine-tool
workpiece-machine-tool
processes is a very complex
mechanical
mechanical and eter
and therange presented.
performance of shear case
angle study
models shear
are provided variation
in Sec-
system during machining processes is a very complex and and
and the performance of shear angle models are provided in Sec-
system during
challenging machining
engineering processes
problem having is aimportant
very complex featuresandat tion the performance
3, while Section of shear angle
4 discusses themodels are provided
video-based chatterindetec-
Sec-
challenging engineering problem having important features tion 3, while Section 4 discusses the video-based chatter detec-
challenging
multiple scalesengineering
both in time problem and having
in space. important features at
The observation at tion 3, while Section
method. Finally, 4the discusses
results are theconcluded
video-based in chatter
Sectiondetec-
5.
1.multiple
Introduction
multiple scales
scales both both in
in time
time and in
in space.
and phenomenaspace. The The observation
observation oftion
tionthemethod.
productFinally,
method. range and
Finally, the characteristics
the results
results are
are concludedmanufactured
concluded in Sectionand/or
in Section 5.
5.
and experimental analysis of such are important in
and
and experimental
termsexperimental
of developing
analysis
analysis of
of such
such phenomena
and validating phenomena
the corresponding
are
are important
important
mechan-
in
in assembled in this system. In this context, the main challenge in
Due
terms of to the
developing fast
and development
validating the in the
corresponding domainmechan- of 2. High-speed
modelling camera is
and analysis system
now not only to cope with single
terms of developing
ical models and results. and The
validating the corresponding
usual time-scale is in the mechan-
range of 2.
2. High-speed
High-speed camera camera systemsystem
communication
ical
ical models
models and
microseconds and forand
results.
results.an The
a typical ongoing
The usual
high-speed trend
usual time-scale
time-scale of digitization
cutting
is in
in the
the range
isprocess. rangeand
Conse-
of
of products, a limited product range or existing product families,
digitalization,
microseconds manufacturing
for a typical enterprises
high-speed are
cutting facing
process. important
Conse- Based
but also to on
be our
ableexperiences
to analyze and andtoliterature
comparestudies,
products thetodynam-
define
microseconds
quently, a possiblefor a typical
solutionhigh-speed
to investigate cuttingchipprocess.
formation Conse-
and Based
Based on
on our
our experiences
experiences and
and literature
literature studies,
studies, the
the dynam-
dynam-
challenges in today’s ics of machine tool vibrations and chip formation processes can
to market environments: a system
continuing new product families. It can beand observed that classical existing
quently,
quently, aa possible
possible solution to investigate chip
chip formation and ics of machine tool vibrations chip formation processes can
other phenomena issolution
use atohigh-speed
investigate camera formation and
dur- ics observed
be of machine tool vibrations
properly at frame andrate chip
of formation
2000 − processes
30,000 fps can
[5,6].
tendency
other towards
phenomena
othermechanical
ing reduction
is
phenomenainvestigations. to use ofa product
high-speed
is to use a high-speed development
In the literature,
camera
camera several times
system and
dur-
system stud-
dur- product
be families
observed are regrouped
properly at frame inrate
function
of 2000 of −
clients
30,000 or fps
features.
[5,6].
ing mechanical be observed
Due to the properly
wide range at of
frame
frame raterates,
of 2000
the − 30,000 fpscamera
high-speed [5,6].
shortened productinvestigations.
lifecycles. Inthe In the
addition, literature,
there is an several stud-
increasing However,
Due to assembly oriented product families are hardly to find.
ing have
ies mechanical
already investigations.
investigated Inchip
the formation
literature, several
process stud-
using Due
system to the
the wide
wideberange
range of
of frame
frame rates,
rates, Inthe
theourhigh-speed
high-speed camera
camera
ies have
demand of already
ies have already
high-speed camera
investigated
customization,
investigated beingthe chip
at the formation
same
the chip itformation
[5–8]. However, time process
should beprocess in a using
global
using
emphasized On theshould
system product
should be
selected
family
selected
carefully.
level, products
carefully. In differ
our
investigations
mainly in twoaa
investigations
system should
Photron FastcambeSA5 selected carefully. In ourwas investigations a
high-speed
competition camera [5–8].
[5–8]. However,
with competitors all overit should
itthe world. be emphasized
theThis trend, main
Photron characteristics:
Fastcam (i)[9]
thehigh-speed
number ofcamera componentsapplied.
and (ii) Thethe
high-speed
that the
camera
that the high-speed
high-speed
camera
camera
However,
experiments
experiments
should
require
require
be
the
emphasized
careful
careful
de-
de- Photron
main Fastcam SA5
specifications SA5of
[9]
[9] high-speed
the high-speed
camera are
camera
camera was
summarized was applied.
applied.
in Table
The
The
1.
which is inducing the development from macro to micro type
main ofspecifications
components (e.g. of mechanical, electrical, electronical).
that the
sign
sign of
high-speed camera
of measurement
measurement
layoutexperiments
layout
and adequately
and adequately
require the careful
chosen
chosen
de-
measure-
measure- main Forspecifications of the
the camera
sufficient magnification, cameratheare summarized
arecamera
summarized in
in Table
Tablewith
was equipped
1.
1.
markets,
sign of
ment results
measurement
parameters, in diminished lot
layoutlighting,
including sizes
and adequately due
resolutionchosen to augmenting
and frame measure-
rate, Classical
For methodologies
sufficient magnification, considering
the mainly
camera wassingle products
equipped with
ment parameters, including macroFor lenses
sufficient
sincemagnification,
the area underthe camera was
observation equipped
is small with
(approx-
product
ment parameters,
for instance. including lighting,
varieties (high-volume lighting, resolution
to low-volume and
and frame
resolutionproduction) frame rate,
[1].
rate, ormacro
macro
solitary,
lensesalready
imatelylenses
since the
1 × 1 since
mm for
existing
area
thechip underproduct families
under observation
areaformation). observation is analyze the
is small
small (approx-
Two commercial (approx-
macro
for
To instance.
cope
for The with
instance. this augmenting variety as well as to be able to product
imately structure
1 × 1 mm onfora physical
chip level (components
formation). Two level) which
commercial macro
goal of this contribution is to present our experiences imatelywere
lenses 1 × 1applied
mm forduringchip formation).
our measurements:Two commercial macro
Nikon Nikkor
The
identify goal
possible
The goal of this contribution
optimization is to present
potentials in ourthe experiences
existing causes
lenses difficulties
were applied regarding
during our an efficient definition
measurements: Nikon and
Nikkor
regarding theof this contribution
instrumentation, is to measurement
optimal present our experiencesset-up and lenses
200 mm were
microapplied during
lens [10] andour Canonmeasurements:
MP-E 65 mm Nikon
macroNikkor
lens
regarding
regarding the
production instrumentation,
system, it is important optimal
to have measurement set-up
set-up and
a precise knowledge comparison
200 of lens
different product families. Addressing this
the instrumentation, optimal
2212-8271 © 2018 The Authors. Published by Elsevier Ltd.
measurement and 200 mm micro lens [10] and Canon MP-E 65 mm macro lens
mm micro [10] and Canon MP-E 65 mm macro lens
2212-8271  c 2018 The Authors. Published by Elsevier Ltd.
This is an 
2212-8271 open
cunderaccess
2018 article under
Theresponsibility
Authors. the CC
Published BY-NC-ND
by Elsevier Ltd. license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
2212-8271
Selection c 2018

and the
The Authors.
peer-review under of the International
Published by Elsevier
responsibility of theScientific
Ltd. Committee
International of the Committee
Scientific 8th CIRP Conference
of the 8thon High Performance Cutting
High(HPC 2018). Cutting
2212-8271
Peer-review© under
2017 The Authors. Published
the responsibility of the by Elsevier B.V.
International Scientific Committee of the 8th CIRP Conference onCIRP Conference on
High Performance Cutting Performance
(HPC 2018).
Peer-review
(HPC under the responsibility of the International Scientific Committee of the 8th CIRP Conference on High Performance Cutting (HPC 2018).
2018).
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
10.1016/j.procir.2018.08.264
156 Szabolcs Berezvai et al. / Procedia CIRP 77 (2018) 155–158
2 S. Berezvai et al. / Procedia CIRP 00 (2018) 000–000

[11]. As their main specifications show (see Table 2) the Canon 3. Case study A: Shear angle estimation
lens ensures better magnification (up to 5:1) and closer focus-
ing distance, although, according to our estimations and tests, In this case study, the predictions of the theoretical shear an-
the depth of field (DOF) is significantly shallower. gle models are compared with the estimated shear angles based
on high-speed camera recordings. The shear angle has signif-
Table 1. Specification of Photron Fastcam SA5 high-speed camera [9] icant role in the theoretical cutting force expressions, thus it
Frame rate 50 − 775,000 fps also affects the dynamics of metal cutting and the occurrence of
Max. resolution 1024 × 1024 pixel (up to 7000 fps) machine tool chatter [1–4].
Shutter 1µs The chip formation process and the shear angle variation
Memory 32 GB (recording duration: 21 − 3 s) can be investigated during stationary cutting with constant chip
thickness (h), which can be realized by orthogonal planning
process. In orthogonal cutting, the material in front of the tool
Table 2. Comparison of the applied macro lenses [10,11] is sheared over a primary zone that is approximated by the shear
plane at the angle Φ. In other words, the shear angle determines
Nikon Nikkor 200 mm Canon MP-E 65 mm
the magnitude and the direction of the cutting force F acting on
Max. Aperture f/4 f/2.8 the tool [12,13].
Magnification 1:1 1:1−5:1
Estimated Depth of Field ≈ 0.55 mm ≈ 0.4 − 0.05 mm
Closest focusing distance 0.5 m 0.24 m a) b)
primary αr
zone
In order to provide sufficient lighting, which is crucial in shear
vc plane
high-speed camera measurements, two Vision Device VD7000 tool tool
LED (max. power 72W) lamps and an endoscope-like Hayashi
h
HDF7010 Fiber Optic LED (max. power 155W) system were Φ Fx
applied. Note, that by increasing the frame rate, the brightness
workpiece Fz
of the image decreases significantly. This effect is illustrated
in Fig. 1/a, where average brightness (Baverage ) obtained from
the HSB values of a test image at different frame rates is pre-
sented for both lenses. Additionally, due to the limited memory Fig. 2. (a) Merchant’s model of cutting forces (b) measured cutting forces ac-
tion on the tool
capacity, the resolution also decreases (see Fig. 1/b). Hence,
the applied frame rate should be selected carefully considering
In the model of Merchant (see Fig. 2/a), the component Fs
also the cutting speed and/or the spindle speed. For instance,
of the cutting force F aligned with the shear plane is obtained
we applied frame rate of 7,000−12,000 fps for chip formation
from the yield shear stress of the material and the shear plane as
(up to vc = 10,000 mm/min) and 10,000−30,000 fps for chatter
Fs = τ s A s . This yields that the other components of the cutting
detection with Ω = 6,000 − 15,000 rpm (see Fig. 1).
force can also be expressed using the tool geometry, namely the
rake angle αr and the average friction angle βa [12,13].
chip a)
formation 3.1. Shear angle models
chatter detection
In the literature, the two most commonly applied shear an-
gle models are based on the maximum shear stress principle
Canon MP-E 65 mm macro (MSSP) and the minimum energy principle (MEP). The MSSP
assumes that the shear occurs in the direction of the maximal
Nikon Nikkor 200 mm macro shear stress, which has an angle of π/4 with the cutting force.
According to Merchant’s circle in Fig. 2, the shear angle can be
expressed using the tool geometry as
π
b) Φ MS S P = − (βa − αr ). (1)
4
However, the MEP states that the power of the cutting force
P = Ft vc should be minimal. This yields, that the shear angle
chip becomes
formation
π β a − αr
chatter detection Φ MEP = − . (2)
4 2

3.2. Method of shear angle estimation

Fig. 1. The dependency of a) average brightness of a test image and b) maximal The planning tests were performed on a single aluminum
resolution on applied frame rate and the applied frame rate regimes (A2024-T351) rib of thickness w = 2 mm using the feed motion
of a NCT EmR-610Ms CNC milling machine. The workpiece
 Szabolcs Berezvai et al. / Procedia CIRP 77 (2018) 155–158 157
S. Berezvai et al. / Procedia CIRP 00 (2018) 000–000 3

was placed on a Kistler 9129AA multicomponent dynamometer

(see Fig. 3). The goal of the measurement was to estimate the
shear angle variation as a function of the uncut chip thickness h.
The planning tests were performed with five different depth of
cut values, namely h = 0.05, 0.1, 0.15, 0.2, and 0.25 mm. The
corresponding parameters of the planning tests are summarized
in Table 3. The shear angle Φ was obtained by evaluating the
theoretical models in Eqs.(1)-(2) based on the measured cut- MSSP
ting forces by applying the expression βa − αr = arctan(F x /Fz ) MEP
according to Fig. 2. Image processing segmentation

tool High-speed Fig. 4. Comparison of the theoretical shear angle models to the image process-
camera system ing method at different chip thicknesses (w = 2 mm, αr = 15◦ , α f = 10◦ ,
w h0 vc = 10,000 mm/min) during orthogonal cutting
z
y
x
vc 4. Case study B: Chatter detection
Canon MP-E
workpiece 65 mm f/2.8 In this case study, a chatter detection method is proposed us-
dynamometer ing high-speed camera recordings. The detection of machine
tool chatter is an actual problem in the industry, for which sev-
Fig. 3. The schematics of the experimental setup eral chatter identification systems are proposed in the literature,
e.g. using microphones and dynamometers [14,15]. Alterna-
tively, machine tool chatter can also be detected based on high-
Table 3. Parameters of the orthogonal cutting speed camera recordings for which a video-based image detec-
Tool Carbide tool, tion algorithm was developed.
wtool = 5 mm, αr = 15◦ , α f = 10◦
Workpiece Aluminum A2024-T351 4.1. Method of chatter detection
w = 2 mm
Process Orthogonal planning, vc = 10,000 mm/min
h = 0.05, 0.1, 0.15, 0.2, and 0.25 mm The video-based chatter detection method was applied dur-
High-speed camera 10,000 fps, Canon MP-E 65 mm macro lens ing stable and unstable milling operations, which were carried
magnification: 5:1 out on an NCT EmR-610Ms CNC milling machine with a ZCC
EMP01-016-G16-AP11-02 tool. The operation parameters cor-
responding to the stable and unstable milling tests are listed in
The chip formation was investigated using high-speed cam- Table 4. The milling tests were also recorded with high-speed
era recordings with 7,000 fps. Since the size of the investi- camera at 10,000 fps using Nikon 200 mm f/4D macro lens
gated phenomena was small, the camera was equipped with a to ensure adequate magnification and depth of field. It should
Canon MP-E 65 mm macro lens to ensure maximal magnifica- be emphasized that reflection from the tool surface is required
tion (5:1). The shear angle was estimated using a displacement- for the image processing method, therefore the lighting system
based image processing technique, where the displacement field should be placed appropriately.
was calculated from two subsequent frames. After applying
Wiener-filtering, the occurrence of the vertical displacement Table 4. Parameters of the milling tests
values indicated the points of the shear plane. The shear angle
Tool ZCC EMP01-016-G16-AP11-02
was obtained from the straight line fitted to the detected points N = 2, d = 16 mm
of the shear plane [5]. Workpiece Aluminum A2024-T351
Process Down-milling, Ω = 8000 rpm, fz = 0.05 mm/tooth
Stable milling: ae = 8 mm, a p = 1 mm
3.3. Measurement results
Unstable milling: ae = 12 mm, a p = 2 mm
High-speed camera 10,000 fps, Nikon 200 mm f/4D macro lens
The detected shear angle and the corresponding standard de- length of recording: 0,1925 s, 1925 frames
viation values can be compared to the prediction of the theoret-
ical models presented in Eqs.(1)-(2). The results show (see Fig.
4), that for small chip thicknesses the prediction of the MEP Based on the high-speed camera recordings, machine tool
model and the image processing method show perfect corre- chatter was detected using the following algorithm. After crop-
spondance. However, during segmentation at high chip thick- ping a small part of the video with well-detectable light pattern
nesses (see the gray shaded area in Fig. 4) both the qualitative on the tool, the video was binarized to black-and-white with
and quantitative prediction of the models became inaccurate. threshold of 0.7 (see Fig. 2). The position of the centre of mass
It should be noted that flying chips and built-up edges caused C(xc , yc ) was calculated for each frame from which the relative
inaccuracy in the image detection algorithm. This may be the displacement of the ith frame in x-direction could be obtained
reason of the high standard deviation values obtained in case of as ∆xc [i] = xc [i] − xc [1]. The spectrum of the vibrations was
image detection on the high-speed camera recordings. obtained using FFT.
158 Szabolcs Berezvai et al. / Procedia CIRP 77 (2018) 155–158
4 S. Berezvai et al. / Procedia CIRP 00 (2018) 000–000
raw video
binarized image
time signal
Fig. 5. The steps of image processing method applied for chatter detection
4.2. Results
The performance of the chatter detection method based on
high-speed camera recordings is presented in Fig. 6. The re-
sults show, that during both stable and unstable milling, the
toothpassing frequency ftp = NΩ/60 ≈ 266.67 Hz, the spin-
dle frequency (due to the runout) f s = Ω/60 ≈ 133.34 Hz and
the corresponding higher harmonics (denoted by green circles)
are well-detectable. Moreover, during unstable milling, further
peaks (denoted by red crosses) occur, which indicate chatter.
These peaks also show symmetry to the higher harmonics of
ftp . Note, that this method can also be applied for small size
milling tools, which cannot be instrumented with accelerome-
ters, therefore non-contact chatter detection method should be
applied.
a) stable
b) unstable
Fig. 6. The measured spectra of a) stable (ae = 8 mm, a p = 1 mm) and b)
unstable milling with chatter (ae = 12 mm, a p = 2 mm)
5. Conclusions
It can be concluded that the presented Photron FASTCAM
SA5 high-speed camera system with Canon MP-E 65 mm and
Nikon 200 mm macro lenses can be applied in the dynamical
analysis of metal cutting using the adequately chosen frame
rate and lighting. The provided case studies showed, that the
machine tool chatter can be detected using the proposed image
detection algorithm. Additionally, the stationary cutting tests
revealed that the theoretical shear angle model based on the
minimum energy principle gives better prediction for the mea-
sured shear angle. However, both the theoretical models and
the shear angle estimation method become inaccurate at chip
thickness values where segmentation appears.
Acknowledgements
This research has been supported by the ÚNKP-17-3-I. New
National Excellence Program of the Ministry of Human Capac-
ities, Hungary.
The research leading to these results has received fund-
ing from the European Research Council under the Euro-
pean Union’s Seventh Framework Programme (FP/2007-2013)
/ ERC Advanced Grant Agreement n. 340889.
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