2240 IEEE/ASME TRANSACTIONS ON MECHATRONICS, VOL. 23, NO.

5, OCTOBER 2018

A Review on Chatter in Robotic Machining

Process Regarding Both Regenerative and
Mode Coupling Mechanism
Lei Yuan , Zengxi Pan , Member, IEEE, Donghong Ding, Shuaishuai Sun,
and Weihua Li , Member, IEEE

Abstract—During the last few decades, industrial robots

have been widely used in various applications to develop a
flexible and efficient manufacturing process such as mate-
rial handling and welding. However, as a high value-added
application, few robotic machining systems have been
installed mainly due to the limitation from the chatter, which
leads to the poor product quality and low productivity.
Although researchers have been continuously investigating
the robotic machining chatter, there is still a lack of under-
standing due to the complexity of the issue. This paper pro-
vides a comprehensive review on chatter-related issues dur-
ing robotic machining tasks, including mechanisms, mitiga-
tion strategies, and identification methods regarding both
regenerative chatter and mode coupling chatter. Due to the
low stiffness and couple structure of industrial robots, both
regenerate and mode coupling chatter can occur at differ-
ent cutting conditions. The difference between two chatter
mechanism in the robotic machining process are compared
and a list of guidelines is provided to help in distinguishing
these two types of chatter. Systemic analysis of the
mechanisms of the chatter identification and suppression Fig. 1. Robotic machining publications per year.
is presented providing a research basis for future studies.
Index Terms—Chatter, mode coupling, regenerative, handling, painting, assembly, machining, etc. [6]–[8]. Among
robotic machining, vibration. them, robotic machining as a high value-added manufacturing
process has attracted significant attention from both academics
I. INTRODUCTION and industry [9]. Fig. 1 shows the number of publications with
ODERN industrial robots offer flexibility, efficiency, low the keywords “robotic/robot machining,” searched in article ti-
M cost, and safety that supersedes many repetitive and haz-
ardous manual operations [1]–[4]. The total number of industrial
tles, abstracts, or keywords in Scopus, considering all documents
published since 1990. Meanwhile, from the industrial perspec-
robots in operation worldwide has been increasing to about 1.5 tive, machining operations account for an estimated 15% of the
million units at the end of 2014 and it is expecting the world‘s value of all mechanical parts manufactured worldwide. In the
industrial robot population would be more than 2 million [5]. USA alone, expenditures on machining are over $250 billion
Today, industrial robots have been widely employed in many per year [10]. However, the inherent structure issues of indus-
industries for various applications, including welding, material trial robots, such as poor accuracy, difficult to program and low
stiffness, limit the wide use of robots for machining applications
Manuscript received September 20, 2017; revised March 25, 2018; [11]–[14], among which the insufficient rigidity is considered
accepted July 18, 2018. Date of publication August 9, 2018; date of as the most significant drawback [15].
current version October 15, 2018. Recommended by Technical Editor Vibration happens in all machining processes to a certain
Prof. L.-M. Zhu. (Corresponding author: Zengxi Pan.)
L. Yuan, Z. Pan, S. Sun, and W. Li are with the School of Mechanical, extent. When not properly controlled, it can result in poor surface
Materials, Mechatronic and Biomedical Engineering, Faculty of Engi- quality, low productivity, and abrasion or damage of the tools
neering and Information Sciences, University of Wollongong, Wollon- [16], as shown in Fig. 2. Moradi et al. [17] categorized the
gong NSW 2522, Australia (e-mail:, ly930@uowmail.edu.au; zengxi@
uow.edu.au; ssun@uow.edu.au; weihuali@uow.edu.au). vibration arose in the machining process into two types: forced
D. Ding is with the School of Mechatronics Engineering, Foshan Uni- vibration and self-excited chatter. Forced vibration is caused
versity, Guangdong 528225, China (e-mail:, dd443@uowmail.edu.au). by time-varying external excitations, for example, the vibration
Color versions of one or more of the figures in this paper are available
online at http://ieeexplore.ieee.org. stems from the regular clash between the teeth of the milling
Digital Object Identifier 10.1109/TMECH.2018.2864652 tool and the workpiece. The forced vibration can be avoided or
1083-4435 © 2018 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications standards/publications/rights/index.html for more information.

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YUAN et al.: REVIEW ON CHATTER IN ROBOTIC MACHINING PROCESS REGARDING BOTH REGENERATIVE AND MODE COUPLING MECHANISM
Fig. 2. Negative effects of machining chatter.
Fig. 3. Two main types of chatter.
Fig. 4. Mechanism of regenerative chatter [18].
prevented relatively easily once the principle vibration source
is identified. Quintana and Ciurana [18] pointed out that the
instability in the machining process is mainly due to the chatter
and it is more undesirable and less controllable compared with
the forced vibration.
Tlusty and Polacek [19] and Merritt [20] identified two most
powerful sources of self-excited vibration (or chatter): regen-
erative chatter and mode coupling chatter, as shown in Fig. 3.
The regenerative chatter occurs when the subsequent machin-
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2241
Fig. 5. Feedback loop of regenerative chatter occurrence [30].
ing on the rough surface after the previous cutting path. During
milling, the next tooth in cut collides with the wavy surface of
the previous tooth and generates a new wavy surface. The chip
thickness and the cutting force vary due to the phase difference
between the wave left by the previous tooth and the wave gener-
ated by the current one [18]. On the other hand, mode coupling
chatter occurs when vibration in the thrust force direction gen-
erates vibration in the cutting force direction and vice versa. For
computer numerical control (CNC) machining, the conventional
wisdom focuses on the regenerative chatter of the machining
tools, such as boring bar and milling cutter, since the mode cou-
pling chatter seldom happens to the CNC machine with large
stiffness of. However, in the robotic machining process, due to
the low structure stiffness of the robot, the entire robot structure
can vibrate before regenerative chatter occurs [21]. The chat-
ter on the robotic machining is a more complicated issue, and
thereby, improving the robotic machining stability has been an
interest of research in recent years.
There are many literatures addressing the chatter issues dur-
ing the machining process including the chatter mechanism and
mitigation strategies. The regenerative chatter mechanism has
been widely studied and reviewed in detail by the authors in [18],
[22], and [23]. Pan et al. [24] claimed that the mode coupling
chatter was the dominant chatter in the robotic milling process;
the occurrence of the chatter during other machining applica-
tions was ignored. Some researchers [11], [25]–[27] presented
reviews of the general vibration/chatter issue during the robotic
machining process, which does not identify the regenerative and
mode coupling chatter, and thereby, there is no corresponding
chatter mitigation method provided.
To accommodate the fast-growing demand and to identify the
challenges in this research area, this paper attempts to provide
a comprehensive review on the chatter in the robotic machining
process including both regenerative and mode coupling chatter.
The rest of this paper is organized into five sections. Following
this introduction, Section II provides regenerative chatter anal-
ysis including its mechanism and chatter reduction strategies.
Section III presents the mechanism and chatter reduction meth-
ods for the mode coupling chatter. A compensative discussion
of two different chatters was provided in Section IV, and finally,
Section V includes a conclusion and future research interests.
II. REGENERATIVE CHATTER
A. Mechanism of the Regenerative Chatter
The regenerative chatter is considered to be the most sig-
nificant cause of the machining instability in a machine tool
2242 IEEE/ASME TRANSACTIONS ON MECHATRONICS, VOL. 23, NO. 5, OCTOBER 2018

TABLE I
SUMMARY OF CURRENT REGENERATIVE CHATTER REDUCTION TECHNOLOGIES

[28]. In the analysis of the regenerative effect, the occurrence

of the chatter includes an interference between the current ma-
chining segment and a wavy surface created from the previous
machining work [24]. During the machining operations, the chip
thickness and the cutting force vary due to the phase difference
between the wave left by the previous teeth (in turning it is the
surface left after the previous revolution) and the wave gener-
ated by the current ones. As shown in Fig. 4, if the surfaces of
the previous cut and current cut are in phase, the dynamic chip
thickness will be constant. If the surfaces are out of phase, the
chip thickness variation would be maximum, and thereby, most
likely to results in a regenerative chatter [29]. From a control
point of view, Fig. 5 illustrates the feedback loop formed [30]
during the regenerative process between the process dynamics Fig. 6. Stability lobes diagram [33].
and structural dynamics of the robotic machining system.
Both offline and online methods can be used for the selection
B. Stability Lobe Diagram (SLD) of the chatter free machining parameters. In offline approach,
the identification of the SLD is completed before the actual
Both selections of stable machining parameters using the machining process.
stability lobe and expansion the stable region on the diagram
through modifying the system behavior are common strategies
C. Offline Approach by Constructing an SLD
for the chatter mitigation as summarized in Table I. Each strat-
egy can be further categorized into two methods with distinct A large number of literature exists in the SLD investigation
characteristics and applications, and more detailed explanations and several approaches have been put forward to identify the
are given below in Table I. stability boundary with a group of cutting parameters for vari-
The SLD is considered as the most effective tool for the ous machining operations [38], [39]. Traditionally, researchers
regenerative chatter analysis [31], [32]. An SLD predicts the established an SLD using analytical approaches due to the lack
occurrence of the regenerative chatter with regard to the cutting of sensing and data processing capabilities. In contrast, the ex-
depth as a function of the spindle speed, as shown in Fig. 6 perimental method constructs and evaluates an SLD without re-
[33]–[35]. SLD plots of the stable and unstable zones by iden- quiring specific knowledge of the machining process [33], [40].
tifying the border between a stable cut (no regenerative chatter) In addition, a combination of the analytical and experimental
and an unstable cut (with a regenerative chatter), by employ- method is also developed taking the advantages of both sides
ing the diagrams, it is possible to obtain a specific combination [28]. However, the story is different for machining using indus-
of machining parameters that results in a maximum material trial robots, which has a much more flexible and complicated
removal rate without chatter [14], [36], [37]. structure than a conventional CNC machine.

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YUAN et al.: REVIEW ON CHATTER IN ROBOTIC MACHINING PROCESS REGARDING BOTH REGENERATIVE AND MODE COUPLING MECHANISM 2243

Although “an SLD is the most reliable method for machining

chatter analysis [41], the conventional method of generating an
SLD is counterproductive due to the variation of dynamic be-
haviors at different robot configurations [14], [21], [42], [43].
The structural mode coupling effect has a great impact on the
dynamic behavior analysis of industrial robots, which results in
surface phase variation, and thereby, occurrence of the regen-
erative chatter. New hybrid approaches to determine the stable
zone of robotic machining tasks combining both the traditional
parameters (depth of cut and spindle speed) and parameters
related to the structural mode coupling effect were developed.
Li et al. [42] explained that different cutting paths and feed
motion would improve the surface quality of the workpiece in
the robotic metal cutting. To verify that, the influence of dif-
ferent cutter paths and workpiece clamping positions related to
a Fanuc-1000i robot on the chatter stability of robotic milling
were tested in their experiment. Then, the corresponding chat-
ter SLDs were plotted based on the modal parameters of both
regenerative and mode coupling effects as shown in Fig. 7(a).
Similarly, Mousavi et al. [43] verify that the feed direction and
position are two noticeable factors that affect the stability of the
process by establishing an SLD for the ABB IRB 6660 indus-
trial robot in the machining process at six different positions
as shown in Fig. 7(b). Wang et al. [21] pointed out that com-
pared to the traditional SLD generation method, which considers
that spindle speed and depth of cut are the two critical factors,
the two most significant factors that influence the stability of
the process are the feed rate and the depth of cut as shown in
Fig. 7(c). Therefore, the corresponding SLD methods consid-
ering mode coupling effect for robotic machining applications
need investigating.
In addition, Rafieian et al. [30] studied the regenerative vi-
brational instability of a robotic grinding operation. A novel
method to construct an SLD that predicted the occurrence of the
regenerative chatter with regard to the system gain (a ratio of the
cutting rigidity over the robot stiffness) as the function of repeat
frequency (a ratio of the spindle frequency over the robot’s first Fig. 7. SLD combining mode coupling effect [21], [26], [42].
natural frequency) was developed. Fig. 8 illustrates the differ-
ence between their proposed approach and conventional SLD
generation method, which demonstrates the maximum depth of
the cut with different spindle speed for CNC machining, the
stable zone of the robotic machining is located far upper right of
the convention stability lobe minimum. The large limiting gain
values in this area can be explained by the cyclic impacting dy-
namics of material removal caused by the robot’s compliance.
Moreover, Hazel et al. [44] pointed out that the conventional
linear modeling method regarding SLD is not suitable for the
practical industrial robot. Therefore, the nonlinear vibro-impact
was illustrated and included in the SLD generation process.
Then, a more actual stable cutting zone was obtained based on
the robotic grinding process.

D. Online Approach for Chatter Avoidance

For industrial robots, due to its articulated serial structure, the
structure dynamics vary at different configurations. It is diffi-
cult to generate a complete SLD for its entire workspace. An Fig. 8. Robotic machining versus CNC machining on the SLD [30].

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2244 IEEE/ASME TRANSACTIONS ON MECHATRONICS, VOL. 23, NO. 5, OCTOBER 2018

Fig. 9. Typical closed-loop control system [41].

Fig. 10. Stability lobes diagram for uncontrolled and controlled
case [47].
alternative method is to tune the machining parameter (spin-
dle speed) online based on the vibration measurement from
sensors. Specifically, the spindle speed can be adjusted in real
time toward the sweet spots on the SLD, resulting in a possible
maximum depth of the cut and higher productivity without ex-
plicitly plotting an SLD. Online chatter avoidance is generally
carried out based on the control schemes and advanced sensing
technologies.
Qin et al. [45] presented a method to collect vibration sig- Fig. 11. Mechanism of mode coupling chatter [51].
nals of the end effector in robotic drilling using two triaxial
accelerometers. Motion of the end effector is decomposed into
boundary based on the advanced control strategy as shown in
the translation motion along the spindle and the plane motion
Fig. 10. The chatter is controlled through real-time monitoring
perpendicular to the spindle. Then, the two accelerometers ob-
the system dynamics, diagnosing the machining process, and
tained the motion signals of the end effector for analyzing the
executing a better action to modify the system to an adequate
vibration occurrence with the use of the rigid body kinematics.
situation. Researchers have been investigating advanced con-
Finally, the effects of accelerometer location and orientation
trol methods to actively compensate regenerative chatter. Özer
were analyzed and demonstrated a successful result. Dai et al.
et al. [47] presented a semiactive control technique to delay
[46] developed a vibration detection method for the robotic
the onset of the chatter when turning with a two-link robotic
milling process using a laser displacement sensor. The authors
arm. The control strategy is based on varying the joint stiff-
pointed out that the laser displacement sensor system can effec-
ness of the robotic arm using a simple ON–OFF type strategy
tively identify vibration signal with a high signal-to-noise ratio.
synchronized with the spindle speed. It was found that SLDs
In addition, the laser sensor works without touching the target,
have been enlarged significantly by comparing between con-
which means it is not needed to design a special mechanism for
trolled and uncontrolled cases as shown in Fig. 10. Wu et al.
mounting it.
[48] also presented an active chatter control strategy to elimi-
Moreover, Fig. 9 illustrates a typical closed-loop chatter con-
nate the external disturbance based on the inverse dynamics of
trol system [41]. The control system determines control action
a robot machine whenever a disturbance signal is detected for
to eliminate a regenerative chatter though the feedback from the
an International Thermonuclear Experimental Reactor (ITER)
sensors, and thereby, various adjustment methods, such as repeat
vacuum vessel process including various machining tasks such
frequency [30] and feed rate [21], can be determined based on
as threading, milling, and boring. Březina et al. [49] designed a
the real-time chatter level information that was obtained from a
PID controller to generate a reactive force for the compensation
sensor feedback.
of the regenerative.
However, it needs to be mentioned that although the cut-
ting condition can be adjusted to reach a stable condition from
chatter, those online schemes are unable to predict the chatter III. MODE COUPLING CHATTER
occurrence in advance, the damage is already imposed on the A. Mechanism of the Mode Coupling Chatter
workpiece surface, which makes an online approach not suitable
Unlike a regenerative chatter, which happens locally at either
for the finishing cuts.
the machine tool or workpiece, when a mode coupling chatter
occurs, the entire robot structure will experience severe vibra-
E. Modification of the System Behavior
tion. The term mode coupling means the vibration exists simul-
Besides avoiding regenerative chatter through choosing a taneously in two or more directions coupling to each other with
group of machining parameters that makes machining in a sta- different characteristics as shown in Fig. 11. The mode coupling
ble zone, the second strategy to control chatter occurrence by chatter happens even when the successive passes of the tool do
changing the system behavior to modify or extend the stability not overlap [50]. Its vibration amplitude has no fixed direction

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YUAN et al.: REVIEW ON CHATTER IN ROBOTIC MACHINING PROCESS REGARDING BOTH REGENERATIVE AND MODE COUPLING MECHANISM 2245

as the tool follows an elliptical path related to the workpiece.

Although it is not common for the modern CNC machine, a
mode coupling chatter can occur in robotic machining at a cut-
ting force much smaller than the robot payload, due to the fol-
lowing two reasons: 1) the low stiffness (typically around as 0.1
∼ 1 N/μm level) of an articulated robot compared to a CNC
machine (commonly above 10 N/μm level); and 2) the articu-
lated serial structure makes the stiffness of the robot at different
directions possibly be very close to each other and varies at
different robot configurations [24].
Fig. 12. Strategies of mode coupling chatter reduction.
Gasparetto [51] studied the phenomenon from the system
theory point of view and provided a valuable 2-D model for the
analysis of the mode coupling chatter as follows:
      the desired direction, which is considered as a passive chatter
M 0 üx Kx 0 ux
+ reduction. Research on the stiffness modeling [52], [53] and
0 M üy 0 Ky u y parameter identification for the stiffness model [54], [55] were
   important to fully understand the robot stiffness distribution
−k sin γ cos γ kcos2 γ ux in its workspace. Owen et al. [56] developed a combined on-
= (1)
−k sin2 γ k cos γ sin γ uy line/offline planning algorithm to optimize the robot trajectories
such that the stiffness is maximized. Guo et al. [57] estab-
where M is the mass of the machining system, and Kx and
lished a robot posture optimization model based on the Jaco-
Ky are the stiffness of the system along the two directions X1
bian matrix to increase the robot stiffness. In addition, Andrisano
and Y1 , respectively.
et al. [58] and Lopes and Pires [59] found that choosing a proper
The characteristic equation of the system was given as
  initial pose and workpiece location would lower the robot load
Kx + Ky Kx Ky + (Ky − Kx ) k sin γ cos γ and ease the joint torques. Lopes and Pires [59] tested a new
λ4 + λ2 + = 0 genetic algorithm to decide the location of the workpiece so that
M M 2
(2) the lower load was added to their robotic model while carrying
the value of λ was obtained as
2 out the same task. Andrisano et al. [58] reduced the external
1    forces on the joints by designing an optimized initial pose for
λ2 = − (Kx + Ky ) ± ΔK (ΔK) + 2k sin2 γ . (3) the robot. In this case, the robot performed the tasks with a lower
2M
joint force so that the less chatter was observed.
According to this equation, the mode coupling chatter only
The second type of the passive chatter mitigation strategy
occurs when the process stiffness k is larger than the difference
is to select the most suitable cutting parameters, since the ma-
of two principle stiffness of the robot δK. In robotic machining,
chining process behaviors, such as cutting direction, machining
chatter limit of the process is configuration dependent due to
tools, and cutting modes can dramatically change the magnitude
the coupled structure of an articulated robot. The mass matrix
and direction of the cutting force. In the research of Tunc and
and stiffness matrix are not constant; they take different values
Stoddart [60], various alternative tool path patterns were eval-
at different robot configurations [24]. Equations (1)–(3) show
uated and the optimum feed direction was selected to reduce
that the stability of the machine tool is not only dependent on
the chatter in a milling process using a Fanuc F200iB hexapod
the stiffness and damping of the system, but also influenced by
robot. Moreover, Pan et al. [24] summarized a series of methods
the interaction of the various modes in the machining system.
to reduce the impact of the chatter on the machining process,
which are as follows.
B. Mode Coupling Chatter Mitigation Strategies 1) A proper selection of a cutting tool would reduce the
The mode coupling theory has been applied by many re- chatter. The geometry of the cutting teeth has a great
searchers for chatter mitigation in the robotic machining pro- impact on the cutting force. For example, the square insert
cess through either passive or active strategies as summarized in is more recommended for robotic machining than the
Fig. 12. To absorb the chatter energy or disrupt mode coupling round insert as it directs less force in the normal direction
effect, the passive strategy addresses the issue through changing to form a feedback loop for the mode coupling chatter.
the robot configuration to maximize the stiffness, optimize pro- 2) Since the robot displays different mechanical properties,
cess behaviors, and modify system structure to chatter absorp- such as stiffness and damping, at different locations in the
tion/disruption, while the active strategy focuses on the force workspace, selecting a proper machining location may
control technology and real-time chatter absorption/disruption. have a more stable process.
Since the stiffness and mass matrices of articulated industrial 3) The tool path and feed direction should be selected prop-
robots varies at different robot configurations, some researchers erly so that the machining force vector aligns with the
investigated the stiffness distribution within the robot work stiffest direction of the robot structure.
envelope and achieved a stable machining process by choos- 4) Chatter is more observed in up-milling than in down-
ing the optimal robot pose and redirecting the cutting force to milling.

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2246 IEEE/ASME TRANSACTIONS ON MECHATRONICS, VOL. 23, NO. 5, OCTOBER 2018

Fig. 13. Principle of the force control strategy.

Other researchers focused on the suppression and absorp-

tion of the chatter energy by changing the system structure.
Conventionally, vibration suppression devices namely dynamic
vibration absorbers (DVAs) are used in the vibration control for
a specific working condition [61]. The working principle of the
DVAs is that the vibration energy of the target subjects would
be largely transferred to the oscillators when the DVAs are de-
signed for a certain condition. For example, in the scheme of
Kaldestad, et al. [62], a sandbag was attached to the spindle as a
passive damper for the robot milling process. The experimental
result showed that it was an effective attempt to reduce vibration. Fig. 14. Robotic milling system with an MRE absorber [70].
Recently, active chatter compensation, in particular, force-
control-based strategy, has been a central topic in a robotic ma-
tation frequencies by employing the adaptive spring element
chining study. Traditionally, robotic machining tasks were per-
that is able to alter its stiffness [69]. Yuan et al. [70] devel-
formed under position control using a conservative travel speed
oped a semiactive chatter reduction device for robotic machin-
and depth of cut so that the machining force does not exceed
ing using magnetorheological elastomers (MREs), as shown in
the limit. The efficiency of the machining process can be opti-
Fig. 14. The MRE absorber was first designed to a frequency
mized by using a controlled material removal rate through force
band close to mode coupling chatter frequency. Then, the de-
control, as demonstrated in Fig. 13. Cen et al. [63] developed
vice was mounted on the spindle of an ABB IRB 6660 robot
an in situ thin-film wireless force sensor to measure the ma-
to mill an aluminium block at various cutting conditions. The
chining forces in a robotic milling operation. More commonly,
experimental results show a certain level of reduction of low-
a commercially available six-degrees-of-freedom force sensor
frequency mode coupling chatter from three group of tests when
was used for the machining force measurement [64]. Using force
the natural frequency matches the target frequency of the robotic
sensor data, Pan and Zhang [65] developed a chatter reduction
spindle. It is worth noting that there are no comprehensive re-
solution through a force control scheme. The controller regu-
search outcomes for active vibration control using an ATVA,
lated the machining force by adjusting the robot travel speed,
such as, mass and damping system [71], capacitive shunting of
avoiding a heavy cut that will result in the chatter. Similarly,
piezoelectric stiffness [72], and MREs [73]. Thus, the effective-
Liang and Bi [66] presented a programmable end effector using
ness of the ATVA is still expected to be investigated due to the
real-time force feedback to adjust operation behaviors such as
complexity of the mode coupling chatter occurred in the robotic
spindle speed, feed rate, stacking sequence, and clamp force.
machining.
In the research of Wang et al. [67], the real-time thrust force
is measured and three stages corresponding to the structures of
the target object are identified based on the analysis of typical IV. DISCUSSION
characteristic parameters of the force profiles. The cross corre- Although vibrations in the robotic machining process have
lation to the standard profiles is adopted to judge the milling been widely studied in recent years, there is still confusion in
status. Moreover, Xie and Sun [68] claimed that force control both academics and industry on which a specific chatter theory
is important to maintain a constant and stable process force for should be applied in a particular situation. Few researchers have
robotic grinding/polishing. clearly distinguished the chatter mechanism in their study. Tra-
Unlike force control that avoids a chatter by limiting the pro- ditionally, the regenerative chatter is commonly regarded as the
cess force, an active chatter control method is to absorb chat- most significant source in machining applications [23]. How-
ter energy by mounting various active vibration absorbers, for ever, other researchers [24], [42], [74] claimed that the mode
example, adaptive tuned vibration absorbers (ATVAs), whose coupling chatter is an intractable problem in the robotic ma-
structure and working principle is similar to DVAs, can vary chining process. In this section, a comprehensive comparison
its natural frequency to track unknown or time-varying exci- of the chatter occurrence and suppression for both regenerative

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YUAN et al.: REVIEW ON CHATTER IN ROBOTIC MACHINING PROCESS REGARDING BOTH REGENERATIVE AND MODE COUPLING MECHANISM
TABLE II
CHATTER DISTINCTION
and mode coupling effect during the robotic machining process
will be provided as a summary shown in Table II.
A. Chatter Identification
Both regenerative and mode coupling chatter were observed
in robotic machining processes. Zhang et al. [50] investigated
the occurrence of both chatters using different cutting tools.
During their experiments, the regenerative chatter was observed
while using a long flexible tool, and a mode coupling chatter
was observed while using a short tool with larger stuffiness.
The authors explained that the different results are due to the
impact of the tool structure that changes the stability boundary
for both chatter mechanisms. To be more specific, Tobias [75]
stated that chatters may occur due to the insufficient dynamic
stiffness of the machining system including machine itself, cut-
ting tool, tool mount, and workpiece. The regenerative chatter
occurs locally at the cutting tool and/or workpiece when the
local structure stiffness is not high enough to avoid regenerative
feedback mechanism. On the other hand, mode coupling chat-
ter occurs when the stiffness of the entire robot structure is not
significantly higher than the process stiffness of the machining
operation. In fact, both regenerative and mode coupling effect
coexists in all robotic machining process. Depending on which
chatter mechanism is the bottleneck, only one type of the chat-
ter phenomena can be observed at a certain machining setup.
Some important guidelines are summarized to provide a better
understanding of chatter properties during robotic machining
processes.
1) Regenerative chatter occurs in machining operations due
to a closed-loop interaction between the machine tool-
part structural displacement and the force process [37].
Thus, a regenerative chatter occurs at the workpiece
and/or cutting tools. While a mode coupling chatter arises
due to the insufficient stiffness and mode coupled struc-
ture of the robot itself, the chatter generally can be ob-
served on the entire robot arm, as shown in Fig. 15.
2) Compared to the conventional machining system with a
large structure stiffness, which means the regenerative
chatter is the main reason to cause vibration, when ma-
chining using an industrial robot, both chatters may occur
depending on the distribution of the stiffness. Thus, iden-
tification of the robot stiffness and process stiffness is
critical in the chatter study. Currently, stiffness modeling
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2247
Fig. 15. Locations of different chatters.
is considered as a common method to predicted stiffness
of the industrial robot [76]–[80]. Moreover, Zhang et al.
[50] pointed out mode coupling chatter arises within a
short stiffer cutting than a long elastic cutting tool.
3) Another feature to identify the chatter type is the differ-
ent frequency ranges. Based on the equation of natural
frequency
1 k
f= (4)
2π m
where f is the natural frequency of the vibration, k is the
stiffness, and m are the mass the structure. Vibration from
different elements of the machining system demonstrates
different frequencies. As the entire robot structure is vi-
brating during the mode coupling chatter, its vibration
frequency is relatively low, around 10–30 Hz [24], [81].
On the other hand, much less mass is involved in a regen-
erative chatter as it happens locally around cutting tool or
workpiece, resulting in a higher chatter frequency, over
hundreds or even thousands of hertz.
4) Many researchers used a force sensor to measure the
process force signal and vibration. Compared to a regen-
erative chatter induced by a small cutting force, a mode
coupling chatter can only occur under a relatively large
cutting force (e.g., hundreds of Newton). Thus, from ap-
plication point of view, the regenerative effect was consid-
ered as the dominant chatter during the finishing process
such as grinding or polishing, which are operated with a
small depth of cut, and thereby, a small cutting force was
generated, while a mode coupling chatter is more likely
to occur during the roughing process, such as milling
2248 IEEE/ASME TRANSACTIONS ON MECHATRONICS, VOL. 23, NO. 5, OCTOBER 2018

The simplicity of the passive strategy made it ideal for vibration

suppression and an active technique is considered as a more ef-
fective method using real-time control and compensation. How-
ever, there is still limited research effort on those strategies for
the robotic machining process. Considering the mode coupled
structure of industrial robots, the effectiveness of the current,
either passive or active, strategy may be undesired.
In addition, there are still some inherent weaknesses of the
existing chatter suppression approaches, the passive strategy is
lack of efficiency and flexibility, which limited the wider use of
the robotic system, and the most active chatter control systems
are very complex and expensive due to extra hardware and
Fig. 16. Stability prediction and selected experimental configuration [82]. software requirements. As there is an additional input energy,
the active system may become a secondary chatter source and
deteriorate the system performance. Therefore, there is still no
and drilling, when a large amount of material is removed single versatile chatter mitigation strategy exists. The chatter
quickly. suppression problem needs to be addressed case by case for
each individual robotic machining setup, as shown in Fig. 16.
To sum up, the chatter phenomenon, which is due to large
B. Chatter Mitigation cutting force combined with the greater flexibility of serial-link
Although researchers have been studying on the regenerative manipulators and self-excited nature of the machining system, is
chatter mitigation during the machining process for decades, the main challenge at present for industrial robots in machining
the story is different for the machining using industrial robots, applications. The regenerative chatter is used to be considered
which has a much more flexible and complicated structure than as the most significant factor of the machining instability in the
a conventional CNC machine. Once the dominant chatter mech- machining system. However, the story is different during the
anism was identified, the suitable chatter suppression strategy robotic machining process due to the elastic and mode coupled
can be used either through an adaption of the regenerative chat- structure, which are the two key factors to cause the mode cou-
ter theory or proposing a new mode coupling theory to mitigate pling chatter. Thus, both regenerative chatter and mode coupling
the special vibration features during the robotic machining. chatter should be regarded as the main source of the machining
First, there is still no general agreement on generating an SLD instability during robotic machining.
for the robotic machining process in the research society. Con-
ventionally, the mechanism of the regenerative chatter implies
that the regenerative chatter occurs due to the wavy surface of V. CONCLUSION AND FUTURE RESEARCH INTERESTS
the workpiece and the same phase of previous and current cuts. This paper provides a comprehensive review on the chatter-
Thus, the regenerative chatter could be avoided by varying the related issues during robotic machining tasks, including mecha-
spindle speed. However, that ignores the mode coupling effect nisms, mitigation strategies, and identification methods regard-
caused configuration-dependent dynamic behaviors of machin- ing both regenerative chatter and mode coupling chatter. Due to
ing tools with low stiffness. In the research of Mousavi et al. the low stiffness and coupled structure of industrial robots, both
[82], an SLD was established based on the regenerative chatter regenerative and mode coupling chatter can occur at different
in robotic milling test as a function of the kinematic redundancy cutting conditions. Although an SLD method for regenerative
variable. It means that stability in the robotic machining can chatter analysis is still valid, the stability lobe changes at dif-
be ensured through the adjustment of the robot configurations, ferent robot configurations and makes it difficult to accurately
which is different from spindle speed variation approach in the measure the SLD offline. Online methods measure the regen-
CNC machining as shown in Fig. 16. Researchers proposed var- erative chatter through various sensor technologies, and then,
ious theories to construct an SLD for the robotic machining as employ either passive or active chatter mitigation strategies to
reviewed in the previous section, such as optimization of cut- absorb the chatter energy or disrupt regenerative effect.
ter paths and workpiece clamping positions [42], feed direction With a poor setup, the mode coupling chatter can occur way
[43], feed rate [21], etc. Therefore, the mode coupling effect below the payload of the robot, which dramatically limits the
should be taken into consideration in regenerative chatter mit- productivity. Compare to the regenerative chatter, there is still
igation and more research effort needs to spend on the general lack of theoretical understanding and practical strategy to tackle
approach to establish an SLD in the robotic machining. the issue. Most of the current studies focus on passive strategies,
Second, a great deal of the literature regarding the chatter which include maximizing structure stiffness, optimising pro-
mitigation were reviewed and classified in [18] and [22]. Be- cess behavior, and chatter absorption. The force control technol-
sides the SLD technology, various passive or active methods ogy was also developed to avoid mode coupling chatter actively
that modify the system behavior is also attempted to deal with through a controlled material removal rate.
chatter issues. Passive strategies aim at improving the machine Due to the complex nature of the robotic machining pro-
tool design, disrupting chatter effect (mode coupled or regener- cess, further researches are required in the aspects of chatter
ative) and employing extra devices to absorb the chatter energy. identification and reduction. The authors have summarized the

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YUAN et al.: REVIEW ON CHATTER IN ROBOTIC MACHINING PROCESS REGARDING BOTH REGENERATIVE AND MODE COUPLING MECHANISM
following issues that are of particular significance for the future
development of chatter free robotic machining applications.
1) Mode coupling effect should be in consideration when
constructing an SLD for the robotic machining.
2) As the current model is too simplified, more detailed
mathematical modeling is required for workspace map-
ping of the mode coupling chatter.
3) More efforts need to be spent on active schemes that
aim at absorbing the chatter energy or disrupting mode
coupled effect to ultimately improve the final quality of
machined parts.
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Lei Yuan received the B.E. degree in mechanical
engineering from the North University of China,
Taiyuan, China, in 2013 and the M.E. degree
in mechatronic engineering from the University
of Wollongong, Wollongong, Australia, in 2017,
where he is currently working toward the Ph.D.
degree in mechatronic engineering.
His research interests include industrial
robots, vibration control, and robotic additive
manufacturing.
Zengxi Pan (M’13) received the B.E. and M.E.
degrees in machine design and mechatronics
engineering from Tsinghua University, Beijing,
China, in 1998 and 2000, respectively, and the
Ph.D. degree in robotics and control engineer-
ing from the Stevens Institute of Technology
Hoboken, NJ, USA, in 2005.
He is currently an Associate Professor
with the University of Wollongong, Wollongong,
Australia. His research interests include indus-
trial robotics, welding technology, and advanced
manufacturing with innovation.
YUAN et al.: REVIEW ON CHATTER IN ROBOTIC MACHINING PROCESS REGARDING BOTH REGENERATIVE AND MODE COUPLING MECHANISM 2251

Donghong Ding received the B.E. degree
in mechanical engineering from the Nanjing
University of Science and Technology, Nan-
jing, China, in 2009, and the Ph.D. degree in
mechatronic engineering from the University of
Wollongong, Wollongong, Australia, in 2016.
He is currently a Professor with the AM
Research Group, School of Mechatronic Engi-
neering, Foshan University, Foshan, China. His
research interests include additive manufactur-
ing, industrial robots, automatic welding, and
computer-aided design / computer-aided engineering software.
Weihua Li (M’15) received the B.E. and M.E.
degrees from the University of Science and
Technology of China, Hefei, China, in 1992
and 1995, respectively, and the Ph.D. de-
gree from Nanyang Technological University,
Nanyang, Singapore, in 2001, all in mechanical
engineering.
He is a currently a Senior Professor and
the Director with the Advanced Manufacturing
Research Strength, University of Wollongong,
Wollongong, Australia. His research interests in-
clude smart materials and their applications, microfluidics, lab on a chip,
rheology, and intelligent mechatronics.

Shuaishuai Sun received the B.E. degree in

mechanical engineering and automation from
the China University of Mining and Technology,
Beijing, China, in 2011, and the Ph.D. degree in
mechatronics engineering from the University of
Wollongong, Wollongong, Australia, in 2016.
He is currently a Research Fellow with the
University of Wollongong. His research interests
include self-sensing self-power magnetorheo-
logical elastomers (MR) devices and smart ma-
terials and structures.

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