Active Control of Regenerative Chatter During Metal Cutting Process

Abstract

Chatter, a violent relative vibration between a workpiece and a cutting tool, is a frequent problem in a machining operation. Among the many factors which contribute to the problem, regenerative chatter is found to be the most detrimental. Optimal control is designed for suppressing regenerative chatter with the critical regenerative effect taken into account. Furthermore, a novel hybrid time and frequency domain approach is developed for generating the stability lobe diagram for the dynamic system after control, since the conventional frequency domain approach is no longer feasible. Numerical results are obtained in both time and frequency domain for verifying the effectiveness of the controller as well as the hybrid approach for generating the stability lobe diagram.

RISE-Based Adaptive Control of a Control Affine Uncertain Nonlinear System With Unknown State Delays

“…To illustrate the performance of the designed RISE-based adaptive controller, we consider the following second order scalar nonlinear system that describes the chattering phenomenon during a metal cutting operation [5], [36]- [38] m y + c _ y + ky = F (y; t)…”

Analysis of regenerative chatter suppression with adding the ultrasonic elliptical vibration on the cutting tool

“…The chatter suppressed by changing tool geometry was investigated experimentally and theoretically by Liu et al [7], Tarng et al [8] and Yang et al [9]. The active controlling approach of regenerative chatter during metal cutting process is given and discussed by Mei et al [10]. The dynamic model, stability and chatter suppression in separating ultrasonic Vibration Cutting were studied by Yu et al [11], Wang et al [12].…”

“…Especially, Chatter suppression becomes more significant for the precision machining and ultra-precision machining of the workpieces with the weak rigidity. Therefore, a large amount of research work has been done on the chatter theory and the chatter suppression [1][2][3][4][5][6][7][8][9][10][11][12]. The theory of regenerative machine tool chatter, the stability of the machine tool against self-exited vibration in machining and the theory of self-excited machine tool chatter were proposed by Tobias et al [1,2], Tlusty et al [3,4] and Meritt [5].…”

Improved sliding mode observer based repetitive control for linear systems with time‐varying input and state delays

“…The presence of time delay is also a challenge in control systems, including those employing RC. Time delay can take two forms: input/output delay, which occurs in the communication between the controller and the plant, such as in the case of input voltage delay in coupled tank liquid level systems 15 or measurement and communication signal delay in generator excitation systems; 16 and state delay, which occurs within the internal operations of the plant, such as in the form of angle position delay, angular speed delay, and voltage delay in power systems, 17 relative displacement delay between tool and workpiece in single-point orthogonal cutting systems, 18 or in the form of intake manifold pressure, exhaust manifold pressure, and compressor power in automotive powertrain systems. 19 The presence of time delay in control systems significantly impairs the tracking accuracy and overall stability of the system.…”