Techniques for suppression of vibration in cutting tools can save old machines and enhance
design flexibility in new manufacturing systems. Structural stiffness interaction, with the
use of smart materials, in an intelligent toolpost is investigated using the finite
element method. The results proved the limited use of lumped modeling in driving
conclusions and developing a toolpost system for dynamic response control. A transient
solution is obtained for the toolpost response in which a smart material actuator is
excited using pulse width modulation (PWM) for voltage generation to counteract
the radial disturbing cutting force. Calculations showed that error elimination
and transient response control require a minimum number of PWM cycles in
each force period. Time delay between the actuation force and voltage has an
adverse effect on error elimination, if it exceeds a certain limit. Increasing damping
within a reasonable range might not eliminate the transient response originated
by the voltage switching of the smart material actuator. The estimated static
voltage in error elimination cannot necessarily be used in dynamic switching. The
tool bit to actuator stiffness and tool carrier (holder) to actuator stiffness ratios
are both preferred to be above ten when space and weight limitations do not
exist.