Mapping model of structure nonlinearity and feedrate for predicting chatter stability in robotic milling
Year: 2025
Type: article
Abstract: The study presents an innovative method for predicting stability lobe diagrams (SLDs) by explicitly incorporating the nonlinear dynamics of robotic milling systems. A frequency-domain decomposition (FDD)-based technique has been devised to systematically identify a comprehensive set of nonlinear frequency response functions (FRFs), from which a systematic mapping relationship between modal parameters, cutting forces, and feedrate is developed. Through this mapping, the complex governing equation of robotic milling is subsequently transformed into a more tractable form to predict SLDs. The significant advancement lies in that a decoupled formulation between modal parameters and excitation forces is established for the first time, thereby simplifying SLD analysis. It also offers the following two advantages over existing methods: (i) enhanced sensitivity in identifying the feedrate-dependent transition between regenerative chatter (RC) and low-frequency chatter (LFC), and (ii) substantial enhancement in the prediction accuracy of SLDs. Experimental results demonstrate that increasing feedrate shifts the RC-LFC transition point toward higher spindle speed regions, with more distinct variation patterns under strong-stiffness conditions. The proposed method achieves an average prediction accuracy of 89.48%, thereby effectively verifying its capability to enhance both the sensitivity and reliability of SLD predictions in robotic milling processes.
Institution: Northwestern Polytechnical University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $4,730
Award: G4855845833
OpenAlex ID: W4416436823