Nonlinearities of hardware-in-the-loop environment affecting turning process emulation

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

“…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.…”

“…However, such setups have less space for mounting and testing actuators that are generally used for controlling vibrations in typical CNC milling machines or portal milling machines. Matsubara et al [6] and Stepan et al [7] , [8] used a realistic machine with an actual spindle unit and a dummy tool/workpiece to emulate chatter vibrations while incorporating speed-dependent dynamics. They, however, did not investigate any active damping strategies.…”

“…They, however, did not investigate any active damping strategies. 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.…”

Effect of axial force on the stability of milling: Local bifurcations around stable islands

“…To avoid the corresponding small-amplitude oscillations consistently, theoretical and/or extensive experimental stability analysis needs to be carried out with respect to the underlying milling operation (see Beri et al (2020); Eynian (2019); Hajdu et al (2020); Stepan et al (2014)). The boundaries of the linearly stable domains indicate the birth of chatter.…”

“…The more precise description of either the material removal mechanism (see Altintas (2012); Stepan (2001); Kurata et al (2010)) or the dynamics of the machine tool (see Budak et al (2006); Kivac and Budak (2004)) helps reduce the extensive and costly laboratory tests in the detection of unwanted vibrations. The recently developed hardware-in-the-loop methodology (see Beri et al (2020); Matsubara et al (2015); Sahu et al (2020); Stepan et al (2019)) also provides an intermediate tool between theoretical modelling and experimental work by carrying out semi-virtual cutting processes.…”