Validation of a hardware-in-the-loop simulator for investigating and actively damping regenerative chatter in orthogonal cutting

Sahu, Govind N.; Vashisht, S.; Wahi, Pankaj; Law, Mohit

doi:10.1016/j.cirpj.2020.03.002

Cited by 17 publications

(21 citation statements)

References 23 publications

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“…HiL simulators have been shown to be useful to investigate chatter [3][4][5][6][7][8][9][10][11][12][13], and to actively control it [3][4][5][9][10][11][12][13]. Ganguli et al [3,4] and Mancisidor et al [5] used a cantilever beam approximating a flexible workpiece and actuators for cutting force emulation.…”

Section: Hardware In Contextmentioning

confidence: 99%

“…Though the setups used in [6] , [7] , [8] are real machines with an actual spindle unit, they are costly. Mancisidor et al [9] , [10] and Sahu et al [11] , [12] , [13] have used a simpler flexure that approximates a linear flexible single degree of freedom workpiece. The flexure used in [9] , [10] , [11] , [12] , [13] provided sufficient space to mount two actuators, one of which imitated cutting forces and the other served as an active damper The simple design facilitated emulations to study the influence of different nonlinear force characteristics on chatter without having to worry about potential nonlinearities in the structure influencing stability.…”

Section: Hardware In Contextmentioning

confidence: 99%

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Hardware-in-the-loop simulator for emulation and active control of chatter

Sahu

Law

2022

HardwareX

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Section: Hardware In Contextmentioning

confidence: 99%

Section: Hardware In Contextmentioning

confidence: 99%

Hardware-in-the-loop simulator for emulation and active control of chatter

Sahu

Law

2022

HardwareX

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“…Thus, the relatively high number of required digital filters causes the delay (phase) in obtaining y(t) to increase. Alternatively, the tool position may be obtained by performing the double integration by means of hardware, as it is done in the recent work [36], which reports good results.…”

Section: Variable Cutting Force Compensationmentioning

confidence: 99%

Active Control of Regenerative Chatter in Turning by Compensating the Variable Cutting Force

Lejarreta

Bárcena

Mancisidor³

2020

IEEE Access

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During metal cutting operations performed by conventional machine tools (turning, milling ...) often appear vibrations due to the emergence of a variable force generated by the so-called regenerative effect. Such vibrations, known as regenerative chatter, may not be prevented at the machine design stage and often limit productivity severely. Therefore, a lot of effort has been put into developing solutions for this problem in the past. To compare the performance of such solutions, it is interesting to realistically reproduce in the laboratory the mentioned regenerative effect in a reliable, repeatable way and covering general machining conditions. With this objective, the paper presents an improvement of a Hardware-in-the-loop chatter simulator that creates this type of vibration for turning machines on a specifically designed mechanical structure. This simulator completely corrects the effects that the delay, introduced by the used equipment (by actuator and controller, mainly), has on the vibration and, moreover, it is capable of imposing general behaviors for any machine with a certain damping factor. Later, by installing inertial actuators on the mentioned structure, the operation of various active chatter control systems may be compared. In this work, the effort made to accurately create the variable machining force is harnessed to try its compensation, by generating with the inertial actuator an approximately inverse control action. In this context, the performance of the novel controller, based on the cancelation of the whole variable cutting force, is analyzed. INDEX TERMSHardware-in-the-loop simulation, regenerative chatter, active control, practical implementation, parameter uncertainty, real-time control, turning machines.

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“…A variation of the spindle speed and thus of the excitation frequency modulates the engagement specific wavelength and disturbs the regenerative effect [31][32][33]. This stabilizing strategy can also be combined with e.g., the use of variable pitch cutters [34].…”

Section: Regeneration Disturbancementioning

confidence: 99%

“…Other investigations target an adaptive variation of the stiffness properties of e.g., the workpiece or tool [34]. An excitation of a dynamically critical system in a specific disturbance frequency [35][36][37] or using an active mode control system [34,38] can suppress or reduce dynamic effects. Moreover, systems based on electrorheological fluids which actively change the eigenfrequencies, and thus suppress the regenerative effect, were analyzed [39,40].…”

Section: Regeneration Disturbancementioning

confidence: 99%

Disturbance of the Regenerative Effect by Use of Milling Tools Modified with Asymmetric Dynamic Properties

Baumann

Wirtz

Siebrecht

et al. 2020

JMMP

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Milling processes are often limited by self-excited vibrations of the tool or workpiece, generated by the regenerative effect, especially when using long cantilevered tools or machining thin-walled workpieces. The regenerative effect arises from a periodic modulation of the uncut chip thickness within the frequencies of the eigenmodes, which results in a critical excitation in the consecutive cuts or tooth engagements. This paper presents a new approach for disturbing the regenerative effect by using milling tools which are modified with asymmetric dynamic properties. A four-fluted milling tool was modified with parallel slots in the tool shank in order to establish asymmetric dynamic characteristics or different eigenfrequencies for consecutive tooth engagements, respectively. Measurements of the frequency response functions at the tool tip showed a decrease in the eigenfrequencies as well as an increase in the dynamic compliance in the direction of the grooves. Milling experiments with a constant width of cut and constantly increasing axial depth of cut indicated a significant increase in the stability limit for the specific preparations of up to 69%.

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Validation of a hardware-in-the-loop simulator for investigating and actively damping regenerative chatter in orthogonal cutting

Cited by 17 publications

References 23 publications

Hardware-in-the-loop simulator for emulation and active control of chatter

Hardware-in-the-loop simulator for emulation and active control of chatter

Active Control of Regenerative Chatter in Turning by Compensating the Variable Cutting Force

Disturbance of the Regenerative Effect by Use of Milling Tools Modified with Asymmetric Dynamic Properties

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