Chatter is an undesirable dynamic phenomenon in machining processes, which causes cutting disturbance, overcut, quick tool wear, etc., and thus seriously impairs workpiece quality. To mitigate chatter, traditional methods called passive control focus on optimizing working spindle speeds and depths of cut. But they have inherent disadvantages in gaining highly efficient machining. On the contrary, the research in this paper is along the line of active control. Specifically, an adaptive algorithm is developed based on Fourier series analysis to deal with the so-called regenerative cutting force which causes chatter. As a result, chatter is remarkably mitigated. The performance improvement is illustrated by numerical simulation in terms of both stability lobes diagram (SLD) and surface location error (SLE).

References

1.
Ding
,
Y.
,
Zhu
,
L. M.
,
Zhang
,
X. J.
, and
Ding
,
H.
,
2011
, “
Milling Stability Analysis Using the Spectral Method
,”
Sci. China, Ser. E: Technol. Sci.
,
54
(
12
), pp.
3130
3136
.10.1007/s11431-011-4611-x
2.
Ding
,
Y.
,
Zhu
,
L. M.
,
Zhang
,
X. J.
, and
Ding
,
H.
,
2011
, “
Numerical Integration Method for Prediction of Milling Stability
,”
ASME J. Manuf. Sci. Eng.
,
133
(
3
), p.
031005
.10.1115/1.4004136
3.
Kern
,
S.
,
Ehmann
,
C.
,
Nordmann
,
R.
,
Roth
,
M.
,
Schiffler
,
A.
, and
Abele
,
E.
,
2006
, “
Active Damping of Chatter Vibrations With an Active Magnetic Bearing in a Motor Spindle Using μ-Synthesis and an Adaptive Filter
,”
Proceedings of 8th International Conference Motion Vibration Control
.
4.
Insperger
,
T.
,
Grandisek
,
J.
,
Kalveram
,
M.
,
Stépán
,
G.
,
Winert
,
K.
, and
Govekar
,
E.
,
2006
, “
Machine Tool Chatter and Surface Location Error in Milling Processes
,”
ASME J. Manuf. Sci. Eng.
,
128
, pp.
913
920
.10.1115/1.2280634
5.
Dohner
,
J. L.
,
Lauffer
,
J. P.
,
Hinnerichs
,
T. D.
,
Shankar
,
N.
,
Regelbrugge
,
M.
,
Kwan
,
C.-M.
,
Xu
,
R.
,
Winterbauere
,
B.
, and
Bridgerf
,
K.
,
2004
, “
Mitigation of Chatter Instabilities in Milling by Active Structural Control
,”
J. Sound Vib.
,
269
(
1–2
), pp.
197
211
.10.1016/S0022-460X(03)00069-5
6.
Smith
,
S.
, and
Delio
,
T.
,
1992
, “
Sensor-Based Chatter Detection and Avoidance by Spindle Speed
,”
ASME J. Dyn. Syst., Meas., Control
,
114
, pp.
486
492
.10.1115/1.2897373
7.
van Dijk
,
N. J. M.
,
Doppenberg
,
E. J. J.
,
Faassen
,
R. P. H.
,
van de Wouw
,
N.
,
Oosterling
,
J. A. J.
, and
Nijmeijer
,
H.
,
2010
, “
Automatic in-Process Chatter Avoidance in the High-Speed Milling Process
,”
ASME J. Dyn. Syst., Meas., Control
,
132
, p.
031006
.10.1115/1.4000821
8.
Insperger
,
T.
, and
Stépán
,
G.
,
2004
, “
Stability Analysis of Turning With Periodic Spindle Speed Modulation Via Semi-Discretisation
,”
J. Vib. Control
,
10
, pp.
1835
1855
.10.1177/1077546304044891
9.
Yilmaz
,
A.
,
AL-Regib
,
E.
, and
Ni
,
J.
,
2002
, “
Machine Tool Chatter Suppression by Multi-Level Random Spindle Speed Variation
,”
ASME J. Manuf. Sci. Eng.
,
124
(
2
), pp.
208
216
.10.1115/1.1378794
10.
Liu
,
K. J.
, and
Rouch
,
K. E.
,
1991
, “
Optimal Passive Vibration Control of Cutting Process Stability in Milling
,”
J. Mater. Process. Technol.
,
28
, pp.
285
294
.10.1016/0924-0136(91)90227-6
11.
Tarng
,
Y. S.
,
Kao
,
J. Y.
, and
Lee
,
E. C.
,
2000
, “
Chatter Suppression in Turning Operations With a Tuned Vibration Absorber
,”
J. Mater. Process. Technol.
,
28
, pp.
55
60
.10.1016/S0924-0136(00)00585-9
12.
Fittro
,
R. L.
,
Knospe
,
C. R.
, and
Stephens
,
L. S.
,
2003
, “
μ-Synthesis Applied to the Compliance Minimization of an Active Magnetic Bearing HSM Spindle's Thrust Axis
,”
Mach. Sci. Technol.
,
7
(
1
), pp.
19
51
.10.1081/MST-120018954
13.
Zhang
,
Y.
, and
Sims
,
N. D.
,
2005
, “
Milling Workpiece Chatter Avoidance Using Piezoelectric Active Damping: A Feasibility Study
,”
Smart Mater. Struct.
,
14
(
6
), pp.
N65
N70
.10.1088/0964-1726/14/6/N01
14.
Shiraishi
,
M.
,
Yamanaka
,
K.
, and
Fujita
,
H.
,
1991
, “
Optimal Control of Chatter in Turning
,”
Int. J. Mach. Tools Manuf.
,
31
(
1
), pp.
31
43
.10.1016/0890-6955(91)90049-9
15.
Chen
,
M.
, and
Knospe
,
C. R.
,
2007
, “
Control Approaches to the Suppression of Machining Chatter Using Active Magnetic Bearings
,”
IEEE Trans. Control Syst. Technol.
,
15
(
2
), pp.
220
232
.10.1109/TCST.2006.886419
16.
van Dijk
,
N. J. M.
,
van de Wouw
,
N.
,
Doppenberg
,
E. J. J.
,
Oosterling
,
H. A. J.
, and
Nijmeijer
,
H.
,
2012
, “
Robust Active Chatter Control in the High-Speed Milling Process
,”
IEEE Trans. Control Syst. Technol.
,
20
, pp.
901
917
.10.1109/TCST.2011.2157160
17.
Insperger
,
T.
,
Wahi
,
P.
,
Colombo
,
A.
,
Stepan
,
G.
,
Bernardo
,
M. D.
, and
Hogan
,
S.
,
2010
, “
Full Characterization of Act-and-Wait Control for First-Order Unstable Lag Processes
,”
J. Vib. Control
,
16
, pp.
1209
1233
.10.1177/1077546309341135
18.
Kubica
,
E. G.
, and
Ismail
,
F.
,
1996
, “
Active Suppression of Chatter in Peripheral Milling. Part II. Application of Fuzzy Control
,”
Int. J. Adv. Manuf. Technol.
,
12
, pp.
236
245
.10.1007/BF01239610
19.
Sims
,
N. D.
, and
Zhang
,
Y.
,
2004
, “
Piezoelectric Active Control for Workpiece Chatter Reduction During Milling
,”
Smart Struct. Mater.
,
5390
, pp.
335
346
.10.1117/12.538761
20.
Krstic
,
M.
,
Kanellakopoulos
,
I.
, and
Kokotovic
,
P. V.
,
1995
,
Nonlinear and Adaptive Control Design
,
Wiley-Interscience
,
New York
.
21.
Ding
,
Y.
,
Zhu
,
L.
,
Zhang
,
X.
, and
Ding
,
H.
,
2011
, “
On a Numerical Method for Simultaneous Prediction of Stability and Surface Location Error in Low Radial Immersion Milling
,”
ASME J. Dyn. Syst., Meas., Control
,
133
, p.
024503
.10.1115/1.4003374
22.
Insperger
,
T.
, and
Stepan
,
G.
,
2002
, “
Semi-Discretization Method for Delayed Systems
,”
Int. J. Numer. Methods Eng.
,
55
, pp.
503
518
.10.1002/nme.505
23.
Insperger
,
T.
, and
Stepan
,
G.
,
2011
,
Semi-Discretization for Time-Delay Systems
,
Springer
,
New York
.
24.
Bachrathy
,
D.
,
Insperger
,
T.
, and
Stepan
,
G.
,
2009
, “
Surface Properties of the Machined Workpiece for Helical Mills
,”
Mach. Sci. Technol.
,
13
, pp.
227
245
.10.1080/10910340903012167
25.
Dombovari
,
Z.
,
Barton
,
D.
,
Wilson
,
R. E.
, and
Stepan
,
G.
,
2011
, “
On the Global Dynamics of Chatter in the Orthogonal Cutting Model
,”
Int. J. Non-Linear Mech.
,
46
, pp.
330
338
.10.1016/j.ijnonlinmec.2010.09.016
You do not currently have access to this content.