Detection of chatter vibration in end milling applying disturbance observer

Suppression of chatter vibration is required to improve the machined surface quality and enhance tool life. For monitoring the chatter vibrations, additional sensors such as acceleration sensors are generally used, which results in high costs and low reliability of the machine tools. In this study, a novel in-process method to detect chatter vibrations in end milling is developed on the basis of a disturbance observer theory. The developed system does not require any external sensors because it uses only the servo information of the spindle control system. Self-excited and forced chatter vibrations are successfully detected. (C) 2011 CIRP.