Multisensor approaches for chatter detection in milling

The development of a chatter detection system for application in industrial conditions was investigated. Several sensors—rotating dynamometer, accelerometers, acoustic emission and electrical power sensors—were compared to determine which signals are most sensitive to chatter onset. The signal characteristics both in time and frequency domain were condensed into a set of chatter indicators, which were further elaborated by means of statistical basic concepts, in order to obtain a chatter identification system. Single-sensor systems and multisensor systems were compared both in terms of accuracy and robustness against malfunctions. Among single sensor systems, the cutting torque signal proved to be a superior signal for chatter identification. Multisensors systems composed of three or four sensors are the most promising solution for reliable and robust chatter identification. The best results were obtained by the multisensor system composed of the axial force sensor and accelerometers.