Robust Active Chatter Control in Milling Processes With Variable Pitch Cutters

Huang, Tao; Zhu, Lijun; Du, Shengli; Chen, Zhiyong; Ding, Han

doi:10.1115/1.4040618

Cited by 25 publications

(5 citation statements)

References 26 publications

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“…Furthermore, SSV methods include some damaging effects on cutting edges which are studied by Albertelli et al [32,33]. In addition to the spindle speed, online variations of other cutting parameters such as cutting angles [34], feed-rate [35], and pitch angle [36][37][38] are used for chatter suppression.…”

Section: Introductionmentioning

confidence: 99%

Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

Hayati

Golmohammadi²,

Valitabar³

et al. 2023

Preprint

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In this study, a milling tool with variable mass and stiffness is developed for chatter reduction. The proposed milling tool is hollow with a solid core threaded inside it. As the core is screwed in or out of the tool body, the equal mass and stiffness of the tool are changed. Therefore, the tool's frequency response function (FRF) is changed to affect the stability lobe diagram (SLD) position. Moving the SLDs can stabilize an unstable cutting process. With respect to the FRFs obtained from modal test, the idea is proven using an experimental and analytical approach. The optimum core position for every spindle speed is also presented. The developed tool stability is then investigated in a realistic cutting condition. The cutting process sound analysis and surface finish visual inspection results reveal the performance of the proposed system in chatter reduction of a slender milling tool.

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Section: Introductionmentioning

confidence: 99%

Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

Hayati

Golmohammadi²,

Valitabar³

et al. 2023

Preprint

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show abstract

“…7 However, high cost and high energy consumption limit the applications of active control systems. 8,9 Semi-active control methods combine the advantages of active and passive control methods, and their parameters can be adjusted in real-time. In addition, the cost and energy consumption of semi-active control methods are relatively low.…”

Section: Introductionmentioning

confidence: 99%

“…7 However, high cost and high energy consumption limit the applications of active control systems. 8,9…”

Section: Introductionmentioning

confidence: 99%

A semi-active control method for magnetorheological dampers to suppress the milling vibration of thin-walled workpieces

Chen

Zhao

Yang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Thin-walled workpieces are widely used in the aerospace field, and milling is the main processing method of such components. However, thin-walled workpieces are prone to vibrate during milling because of their weak stiffness, and the vibrations significantly affect the processing quality. Therefore, it is important to develop a novel milling vibration suppression method for thin-walled parts. The present work focused on the milling vibration control of a thin-walled workpiece using a semi-active magnetorheological (MR) damper. The forward dynamic model and inverse control model of the MR damper were first established, and its actuating position on the workpiece was then determined by modal analysis. The dynamic model of the MR damper at this position was built based on the proposed dynamic parameter acquisition method and used in the following semi-active control algorithm design. The effectiveness of this algorithm was verified by MATLAB/Simulink simulations. Finally, six groups of milling experiments were carried out using the non-damper, the rigid rod, the damper applied with 1-, 2-, and 3-A currents, and the semi-active control damper to validate the practical effect of the proposed algorithm. It was found that the designed semi-active control MR damper outperformed the constant-current control dampers or the rigid rod. In comparison to the non-damper experiment, the root mean square (RMS) values of milling forces in x- and y-directions decreased by 45.12% and 48.58%, respectively, and surface roughness decreased by 40.22%.

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“…The disadvantage of this method was that the pallet system was similarly susceptible to machining vibration. Huang et al developed a feedback controller built on linear matrix inequality using multiple delay differential equations (Huang et al, 2018). He increased the stability domain in the stability lobe diagram through off-line adjustment.…”

Section: Introductionmentioning

confidence: 99%

A feedback controller for milling chatter vibration control using a new response matrix

Muhammad

Bashir

Hamza

et al. 2021

Journal of Vibration and Control

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A chatter mark is a result of irregular vibration that affects the milling process, which results in poor surface finish, reduced work quality, machine impairment, and high production cost. This work presents an active feedback controller design using a new response matrix to suppress the free vibration in the milling process. The proposed controller considers feed rate, tooth passing frequency, and time-varying dynamic milling force coefficients. A milling experiment verifies the effect of the proposed method. The method provides a reliable way of tackling chatter vibration in an industrial process. The procedure is technically and economically beneficial.

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Robust Active Chatter Control in Milling Processes With Variable Pitch Cutters

Cited by 25 publications

References 26 publications

Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

A semi-active control method for magnetorheological dampers to suppress the milling vibration of thin-walled workpieces

A feedback controller for milling chatter vibration control using a new response matrix

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