Investigation of the low-frequency chatter in robotic milling

In robotic milling with large allowance process, low-frequency chatter (LFC) is an important factor observed in high-speed and low-speed milling, affecting the processing efficiency and quality. Previous research has used the regenerative chatter theory, ignoring modulated tool-workpiece engagement conditions, or mode coupling theory under the assumption of threading operations to explain the LFC mechanism and predict the stability boundary. However, these models overlook or inaccurately characterize the modulation effect, leading to inaccurate modeling of dynamic chip thickness changes during milling, making it difficult to understand the mechanism of LFC. Here, we propose an LFC stability model that considers modulated tool-workpiece engagement conditions and the mode coupling effect of the robotic structure for robotic milling. This approach allows us to reveal the mechanism of LFC and identify the characteristic signal of low-frequency vibration, which is the sideband frequency signal. Initially, the evolution of LFC is analyzed, and its characteristics are summarized. Further, a surface renewal (SR) model is proposed to accurately calculate the dynamic cutting force caused by modulated tool-workpiece engagement conditions in LFC. Furthermore, the LFC stability model, considering the modulated tool-workpiece engagement conditions and mode coupling effect, is established based on impulse response function (IRF) method. Finally, we verify the accuracy of our model through milling experiments and compare it with that of the classical stability prediction model. Our results show that LFC is highly dependent on speed, and our stability model can effectively predict the stability boundary of LFC in robotic milling with large allowance process.