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Online chatter monitor system based on rapid detection method and wireless communication

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Abstract

Chatter is a serious self-excited vibration, which can lead to many issues in machining; thus, an effective online chatter detection method is highly demanded. However, the pre-processing such as decomposition on the collected signals that was usually used in the literature costs a long time, thus compromising its online capacity. In this study, a rapid chatter detection method is investigated aiming at establishing a monitor system based on wireless communication. Firstly, the feasibility of not using pre-processing on vibration signals in milling chatter detection was demonstrated. Fractal dimension (FD) algorithms, including Katz’s and Higuchi’s approaches, and power spectral entropy algorithm, as well as a typical pre-processing method, empirical mode decomposition (EMD), were studied comparatively. It was found that Katz’s FD without EMD can monitor chatter effectively and the most rapidly; thus, it can be considered as the most favorable option for chatter monitor within the scope of this study. Based on such a finding, an online chatter monitor system was established by using Zigbee wireless communication technique. The comprehensive performance, including time cost, power consumption and packet loss rate of the established system were tested. The signal credibility and ability to monitor chatter of the system was also verified in practical milling, suggesting that it could meet the requirements of online chatter monitor.

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Availability of data and materials

The data presented in this study are available upon request with reasonable causes from the corresponding author.

Code availability

The custom codes used in this study are available upon request with reasonable causes from the corresponding author.

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Acknowledgements

The authors would like to thank Mr. Binbin Liu, Mr. Shaocong Wang and Mr. Yousheng Xia of Tsinghua University for their efforts in establishing the calculation programs of fractal analysis.

Funding

This study was supported by National Natural Science Foundation of China under Grant No. 51875311, Guangdong Basic and Applied Basic Research Foundation under Grant No. 2020A1515011199, and Shenzhen Foundational Research Project under Grant No. WDZC20200817152115001.

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Author notes

  1. Xueyu Mei and Haoming Xu contributed equally to this work.

Authors and Affiliations

  1. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Xueyu Mei, Haoming Xu, Pingfa Feng & Feng Feng

  2. Division of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen, 518055, Guangdong, China

    Xueyu Mei, Haoming Xu, Pingfa Feng, Meng Yuan & Feng Feng

  3. Department, Shenzhen Tsingding Technology Co. Ltd., Shenzhen, 518133, Guangdong, China

    Chao Xu & Yuan Ma

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  1. Xueyu Mei
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Contributions

The authors Xueyu Mei, Haoming Xu and Feng Feng carried out the research and wrote the original manuscript. Pingfa Feng, Yuan Ma and Chao Xu assisted with conceptualization of the investigation. Meng Yuan assisted with the data analysis and manuscript editing. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Feng Feng.

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Mei, X., Xu, H., Feng, P. et al. Online chatter monitor system based on rapid detection method and wireless communication. Int J Adv Manuf Technol 122, 1321–1337 (2022). https://doi.org/10.1007/s00170-022-09941-3

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