Analysis and compensation of mass loading effect of accelerometers on tool point FRF measurements for chatter stability predictions

Chatter is one of the major problems in machining resulting in poor surface quality and reduced productivity. Stability diagrams can be used to determine chatter-free process conditions yielding high productivity. For generation of stability diagrams, frequency response functions (FRF) at the tool tip are needed to be used in stability models. Impact tests involving accelerometers are commonly used in FRF measurements. Although mass of a typical accelerometer used in these measurements is extremely small compared with the cutting tool, it can have a significant effect on the FRF measurement. In this paper, the effect of accelerometer’s mass on tool point FRFs and stability diagrams is demonstrated for several cases with different tool-to-accelerometer mass ratios by using laser velocity sensor measurements. In addition, a structural modification method which can be used to compensate this effect is also presented on several cases. The structural modification method can be used to correct the FRFs measured with accelerometers, and thus the resulting stability diagrams.