Comparison between microphone and accelerometer signals for chatter identification in milling processes

Abstract

Abstract Machining operations may lead to chatter, a harmful phenomenon to the process that has to be avoided. The chatter identification is an important method to understand the machining process through the vibrations signals and avoid the conditions where chatter is more likely to be present. In this work, two approaches for milling chatter identification were studied, the first one using the signal by a microphone sensor and the second one using accelerometers in two different points, with the objective of making a comparison of which is the most suitable for a case with a long tool and low axial depth of cut. Frequency and time domain analyzes were performed, the results for both cases show the chatter in a specific cutting condition, however, the regenerative phenomenon was more evidently identified through the microphone. The obtained results will also be used in a practical context for the validation of a Stability Lobe Diagrams under development.