Position dependent vibration evaluation in milling of thin-walled part based on single-point monitoring

Existing monitoring methods with dynamometers place higher requirements on hardware facilities, and its accuracy varies with different equipment. To monitor the milling process more conveniently and accurately, a low-cost and adaptable single-point monitoring method based on one acceleration sensor is proposed. Starting from the monitored vibration data of the workpiece, the vibration attenuation characteristic of a single monitoring point with respect to different processing positions is used to establish a spatial vibration attenuation model, and an acceleration correction coefficient matrix is obtained to further calculate the vibration intensity at any processing position. Based on the developed models, the relative errors between the measured and calculated cutting force under strong and weak vibration conditions are analyzed. Experiments results show that errors less than 20% account for 93% of all the data and the average error is about 10%, which effectively proves that the model has high precision and accuracy.