Design of a Force Feedback Chatter Control System

Abstract

The analysis of machine tool chatter from frequency domain considerations is generally accepted as a valid representation of the regenerative chatter phenomenon. However, active control of regenerative chatter is still in its embryonic stage. It was established in reference [2] that a measurement of the cutting force could be effectively used in conjunction with a controller and a tool position servo system to increase the stability of an engine lathe and to improve its transient response. This paper presents the design basis for such a system, including both analytical and experimental considerations. The design procedure stems from a real part stability criterion based on the work by Merritt [1]. Because of the unknown variability in the dynamics of a machine tool system, the controller parameters were chosen to accomodate some mismatch between structure and tool servo dynamics. Experimental tests to determine the stability zone of the controlled machine tool system qualitatively confirmed the analytical design results. The experimental results were consistent in that the transient response tests confirmed the frequency domain stability tests. It was also demonstrated experimentally that the equivalent static stiffness of a flexible work-piece system could be substantially increased.

Simulation and Active Control of Chatter in Milling via a Mechatronic Simulator

“…Active vibration control strategies have also been applied for chatter control. Glaser et al (1979) and Nachtigal (1972) propose a feedforward strategy of using the cutting force signal for chatter control in turning. An adaptive control technique, using a filtered-X least mean square algorithm has been proposed by Browning, Golioto, and Thompson (1997) for chatter suppression in boring bars.…”

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

“…Active solutions can overcome these limitations and it is why they have been extensively studied. These active systems are roughly based on measuring the vibration and generating a force response that attempts to reduce the effect of the chatter, by means of a sensor-actuator pair placed near the tool [15] [16] [18] [20] [21] [23] or on the machine structure [14][17] [19] [22], which guarantees adaptability to changing conditions.…”

Time-delay feedback control of lathe cutting tools

“…Redmond et al (1999), Browning et al (1997), and Nayfeh (1997, 1999) concluded that biaxial control is necessary to ensure satisfactory chatter suppression. Nachtigal (1972) proposed a feed-forward approach for control of chatter in the lathe and Glaser and Nachtigal (1979) extended it to boring operations. Shiraishi et al (1991) implemented an optimal control strategy to mitigate chatter in turning.…”