Incipient chatter fast and reliable detection method in high-speed milling process based on cumulative strategy

This paper proposes an incipient chatter detection method to meet high dynamic applications' time and reliability constraints, such as high-speed milling involving heavy noise. The herein introduced method relies on a multiple sampling per revolution (MSPR) technique, coupled with two data preprocessing techniques, a modified adaptive cumulative chatter indicator, and a two-risk levels-based threshold. The MSPR technique enables collecting information-rich enough data to characterize the chatter dynamics thanks to a significant amount of data collected in each revolution. Therefore, the MSPR technique allows for acquiring the data using a short-time window, thus reducing the detection delay. Two data preprocessing techniques, i.e., Z-score normalization and mean-centered, are implemented for data integration and chatter information consolidation. The modified adaptive cumulative chatter indicator has three advantages: (a) it accumulates the information on the chatter feature and highlights the appearance of an incipient chatter; (b) it adapts to the variation of the environmental disturbance noises, resulting in enhanced detection reliability; (c) it is faster than the adaptive cumulative log-likelihood ratio (ACLLR) for decision-making statistically. The two-risk levels-based threshold overcomes the limitations of a unique threshold, and allows simultaneously assessing the two risk levels, thus improving detection reliability. We successfully applied the proposed method to detect incipient chatter in a digital high-speed milling process and assessed its effectiveness by comparing it with several existing chatter detection methods.