Correlation analysis of dynamic signal characteristics during whirlwind milling

Abstract

Cutting vibration and cutting force are two critical physical variables that offer valuable insights into the screw whirling process. Most previous studies have focused on experimental characterisation or tool motion analysis, lacking research on the intrinsic coupling relationship between vibration and cutting force. This has resulted in a lack of systematic understanding of the dynamic interaction processes within the machining system. This study performs appropriate phase space reconstruction (PSR) on one-dimensional milling signals and uses it to draw a cross-recursive plot (CRP). Based on the structural characteristics of the image, the correlation between signals is discussed qualitatively. A subsequent cross recurrence quantitative analysis (CRQA) is employed to quantitatively evaluate the correlation across different process parameters. Unlike traditional non-linear analysis techniques, the cross-recursive method can capture coupling properties in short-term, non-stationary, non-linear signals. This paper is the first to apply the cross-recursive method to the study of the correlation between vibration and cutting force in dry whirlwind milling. The research results indicate that there is a good continuous correlation between vibration and cutting force under certain combinations of process parameters. At high cutting speeds (V_t = 180 m/min), the use of multiple cutting tools (N_t = 6) significantly reduces the correlation and stability between vibration and force (by approximately 30–35 %). However, at low cutting speeds (V_t = 60 m/min), the use of multiple cutting tools enhances the correlation (by approximately 20 %).