Evaluation of Sensor-less Identification Method for Stable Spindle Rotation against Chatter with Milling Simulation Analysis

Although chatter stability analysis is necessary to enhance cutting accuracy and efficiency, a reliable prediction is difficult to achieve because of the analysis error of frequency response function. Therefore, the investigation proposes an experiment-based identification method for stable spindle rotations in milling by gradually changing the spindle rotation and capturing chatter frequency shift from servo information. In order to evaluate the identification accuracy, this paper presents theoretical approaches to analyze time-dependent variation in chatter and the expected identification error of proposed method by using a time-domain simulator and a frequency-domain model considering amplitude ratio between inner and outer modulations of the chip.