Main Spindle Speed Variation Mapping for Chatter and Motor Limits
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Solution Overview
Problem
Machine tools experience chatter vibration due to low rigidity, leading to tool loss and surface accuracy deterioration, and existing monitoring systems cannot determine if chatter vibration reduction is achieved within motor output limits, resulting in inefficient trial machining.
Innovation Solution
A monitoring device for machine tools that displays a variation diagram of rotation speed, showing the relationship between amplitude and cycle, along with a reduction effect index calculated based on speed ratios, and an output limit line, allowing for optimal machining condition selection to reduce chatter vibration within motor limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rotation speed variation is applied to reduce chatter vibration, then chatter vibration reduction effect is improved, but it is difficult to determine whether the reduction effect is sufficient within motor output limits
Solution Approach 1:
The system calculates a reduction effect index based on the ratio between actual rotation speed and reference rotation speed, providing real-time feedback on the chatter vibration reduction effect. This allows operators to determine whether the variation is sufficiently reducing chatter vibration while staying within motor output limits, eliminating the information gap identified in the contradiction.
2Manufacturing precision
If trial machining is repeated to find optimal machining conditions, then chatter vibration reduction is attempted, but productivity is impaired
Solution Approach 1:
The system calculates and displays the reduction effect index before trial machining, allowing operators to predict the chatter vibration reduction effect in advance. This preliminary information enables selection of optimal rotation speed variation parameters without repeated trial machining, thereby improving productivity while achieving chatter vibration reduction.
3Manufacturing precision
If rotation speed variation amplitude and cycle are increased to reduce chatter vibration, then chatter vibration reduction is improved, but motor output limits may be exceeded
Solution Approach 1:
The reduction effect index provides continuous feedback on the relationship between rotation speed variation parameters and chatter vibration reduction effect. Operators can use this information to adjust variation amplitude and cycle within motor output limits, achieving optimal chatter vibration reduction without exceeding power constraints.
Data Source
AI summary
A monitoring device of a main spindle rotation speed in a machine tool displays a variation state of the rotation speed by a rotation speed variation unit using a display unit in the machine tool. The monitoring device includes a drawing unit, a variation position display unit, and a reduction effect index display unit. The drawing unit is configured to display a variation diagram that illustrates a relationship between a variation amplitude and a variation cycle of the rotation speed. The reduction effect index display unit is configured to display a reduction effect index on the variation diagram. The reduction effect index represents a reduction effect of chatter vibration. The reduction effect index is calculated based on a speed ratio that is a ratio of a rotation speed of one rotation before to a rotation speed at an identical rotation position of the main spindle at any given timing.