Dynamics of stainless steel turning: Analysis by flicker-noise spectroscopy

TL;DR

This paper applies flicker-noise spectroscopy to analyze and identify chatter vibrations in stainless steel turning, revealing the transition from regular to noisy oscillations and proposing frictional interactions as the cause.

Contribution

It introduces flicker-noise spectroscopy as a novel phenomenological method for analyzing stochastic dynamics in turning processes, providing new insights into chatter vibrations.

Findings

Chatter vibrations are linked to high-frequency noisy oscillations.

Flicker-noise spectroscopy effectively characterizes stochastic dynamics.

Frictional stick-slip interactions may cause chatter.

Abstract

We use flicker-noise spectroscopy (FNS), a phenomenological method for the analysis of time and spatial series operating on structure functions and power spectrum estimates, to identify and study harmful chatter vibrations in a regenerative turning process. The 3D cutting force components experimentally measured during stainless steel turning are analyzed, and the parameters of their stochastic dynamics are estimated. Our analysis shows that the system initially exhibiting regular vibrations associated with spindle rotation becomes unstable to high-frequency noisy oscillations (chatter) at larger cutting depths. We suggest that the chatter may be attributed to frictional stick-and-slip interactions between the contact surfaces of cutting tool and workpiece. We compare our findings with previously reported results obtained by statistical, recurrence, multifractal, and wavelet methods. We discuss the potential of FNS in monitoring the turning process in manufacturing practice.