Machine Tool Chatter Identification Based on Dynamic Errors of Different Self-Synchronized Chaotic Systems of Various Fractional Orders

Chatter, the vibration between the workpiece and cutting tool, is a common phenomenon during the milling process. Traditionally, the Fourier transform analysis is mainly used to extract the features and determine whether chatter occurs. In this paper, an innovative and practical chatter identification method combining fractional order chaotic system and extension theory is proposed. A lathe spindle with embedded sensors is used in this study. The boundary of chattering state of the lathe spindle is decided by the center of gravity of phase plane of dynamic errors. The boundaries are then fed into extension model and relational function calculation is performed. In this way, chatter identification can be easily achieved based on the position of the chaotic center of gravity. The three chaotic systems, i.e. Lorenz, Chen-Lee, and Sprott, of different fractional orders are used and their results are compared. Compared with the traditional methods, the Fourier transform is time-consuming in terms of mathematical operations and adverse to the establishment of a real-time system. This paper uses the characteristics of the chaotic systems sensitive to input signals in order to more capably detect the boundary state from normal cutting to chattering cutting and more efficiently identify the chatter. The experiment results indicate that the Chen-Lee system (93.5%) exhibits have better chatter diagnosis rate than Lorenz (92.75%) and Sprott (69%) systems. The Chen-Lee system even reaches a diagnosis rate of 100% for orders 0.5 ~ 0.7. Therefore, the method presented in this paper has a very high diagnosis rate and is thus very effective for chatter identification of machine tools.