Sharif Digital Repository

For various types of materials, milling process is extensively used to generate complex shapes with high quality. During the process and to achieve high removal rate, precision and better surface finish, chatter suppression is of great importance. An extended model of the milling process is presented in which the cutting forces are described as a third-order nonlinear function of chip thickness. Uncertainties associated with the process and tool parameters are also included to achieve a more realistic model. To suppress regenerative chatter, an H∞ robust control is designed based on µ-synthesis with DK-iteration algorithm. The controller guarantees the robust stability and performance of... 

During the milling process, self-excited vibration or chatter adversely affects tool life, surface quality and productivity rate. In this paper, nonlinear cutting forces of milling process are considered as a function of chip thickness with a complete third order polynomial (instead of the common linear dependency). An optimal control strategy is developed for chatter suppression of the system described through nonlinear delay differential equations. Counterbalance forces exerted by actuators in x and y directions are the control inputs. For optimal control problem, an appropriate performance index is defined such that the regenerative chatter is suppressed while control efforts are... 

This paper deals with the problem of chatter suppression in milling process in order to achieve higher precision, better surface quality and larger material removal rate (MRR). The peripheral milling process is modeled as a two degrees of freedom system and the effects of tool wear and process damping are considered. It is shown that when regenerative chatter develops, both tool wear and process damping act as stabilizing factors. For larger values of depth of cut and consequently higher MRR, tunable vibration absorbers (TVA) (in x-y directions) are designed to improve stability. An optimal algorithm is developed which determines the optimum values for absorbers' parameters. The effects of... 

In this paper, a tunable vibration absorber (TVA) is designed to suppress regenerative chatter in milling of cantilever plates. In machining industry, the majority of work-piece materials or the interaction of work-piece/cutting tool causes the cutting forces to demonstrate nonlinear behavior. The application of TVA (as a semi-active controller) is investigated for the process with an extensive nonlinear model of cutting forces. Under regenerative chatter conditions, optimum values of the absorber position and its spring stiffness are found such that the plate vibration is minimized. For this purpose, an optimal algorithm is developed based on mode summation approach. Results are presented... 

In the machining processes, vibration suppression is crucial in order to achieve the high precision as well as high-quality surface and increase of the material removal rate. In this paper, an adaptive sliding mode control approach is presented to supress the chattering phenomenon in the boring process in the presence of model uncertainties and unmodeled dynamics. The boring bar is modeled as a cantilever Euler–Bernoulli beam, which is actuated by a piezo-actuator located at the bar's end. As a more realistic model, the cutting tool is modeled as an added mass at the bar's end. In order to derive the equations of motion, mode summation method with inclusion the first three modes of vibration... 

Chatter suppression is an important topic in any type of machining process. In this paper, orthogonal cutting process is modeled as a single degree of freedom dynamic system. A nonlinear delay differential equation is presented that models flank wear of the tool. Uncertainties in cutting velocity, tool wear size and parameters of the dynamic model are included in the model of cutting process. The force provided by a piezo-actuator is taken as the control input of the system. A sliding mode control scheme is used and an effective control law is derived which suppresses the chatter vibration. Results for two distinct cases of a sharp tool and a worn tool are presented and compared which shows... 

Peripheral milling is extensively used in manufacturing processes, especially in aerospace industries where end mills are used for milling of wing parts and engine components. The generation of complex shapes with high quality for various types of materials is the main advantage of milling in contrast to other machining processes. During the milling process, the occurrence of self-excited vibrations or chatter may cause reduction in material removal rate (MRR), damage to the tool and spindle bearing or may result in poor dimensional accuracy and surface finish of the work-piece. In this paper, milling process is modeled as two degrees of freedom (2DOF) system in which the tool wear and... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, two control strategies are developed to suppress chatter vibration in the turning process including a worn tool. In the first stage, a sinusoidal spindle speed variation around the mean speed is modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. In the second stage, to improve the response of the system which is associated with small ripples under the steady state condition, an adaptive controller is designed. In... 

Dynamic vibration absorbers are used as semi-active controllers to reduce the undesirable vibrations in many applications such as electrical transmission lines, helicopters, gas turbines, engines, bridges and etc. One type of these absorbers is tunable vibration absorber (TVA). In this paper, regenerative chatter in an orthogonal turning process is suppressed using a (TVA). It is shown that TVA can modify the frequency response function of the cutting tool so as to improve cutting stability in turning process. In addition, tool wear is an important factor which works as a positive damping and helps the chatter suppression beside exertion of the TVA. Finally, using the SIMULINK Toolbox of... 

Dynamic vibration absorbers are used as semi-active controllers to reduce the undesirable vibrations in many applications such as electrical transmission lines, helicopters, gas turbines, engines, bridges and etc. One type of these absorbers is tunable vibration absorber (TVA). In this paper, regenerative chatter in an orthogonal turning process is suppressed using a (TVA). It is shown that TVA can modify the frequency response function of the cutting tool so as to improve cutting stability in turning process. In addition, tool wear is an important factor which works as a positive damping and helps the chatter suppression beside exertion of the TVA. Finally, using the SIMULINK Toolbox of... 

Chatter suppression is of great importance in machining processes for achieving more material removal rate, high precision and surface quality. In this paper, an H∞ control algorithm is proposed for chatter suppression in the presence of tool wear and parameter uncertainties. Orthogonal turning process is modelled as a single degree of freedom model that includes the effect of tool flank wear. Control input of the system is the force provided by a piezo-actuator.The turning process model includes the uncertainties in cutting velocity, tool wear and dynamic model parameters. Using the μ-synthesis technique, an H∞ optimal controller is designed based on a DK-iteration algorithm. The... 

High-quality, high-production-rate machining operations are significantly hindered by the regenerative chatter. Therefore, chatter suppression is of great significance; and active control is one of the best ways to curb it. In this paper, the orthogonal turning process is modeled as a single-degree-of-freedom system that includes the effect of tool wear; and described through a delay differential equation (DDE). Based on the model, stability lobes diagrams are obtained by the trial and error. The actuator force is the input for the control system and the tool vibration is the output. A classical PID controller is designed to improve the stability of the process and curb the self-excited... 

Chatter suppression is of great importance for achieving high precision and surface quality in machining processes. A single degree of freedom model of orthogonal turning process is used to set up the nonlinear delay differential equation of motion. Tool wear effect is considered as the contact force between the workpiece and tool flank surfaces. Uncertainties in parameters of dynamic model and machining conditions are included in the model. An adaptive control strategy is applied for chatter suppression in cutting process. The force provided by a piezoactuator is the control input of the system. Results of stability analysis and adaptive control for two distinct cases of sharp and worn... 

In this paper, a tunable vibration absorber set (TVAs) is designed to suppress regenerative chatter in milling process (as a semi-active controller). An extended dynamic model of the peripheral milling with closed form expressions for the nonlinear cutting forces is presented. The extension part of the cutting tool is modeled as an Euler-Bernoulli beam with in plane lateral vibrations (x-y directions). Tunable vibration absorbers in x-y directions are composed of mass, spring and dashpot elements. In the presence of regenerative chatter, coupled dynamics of the system (including the beam and x-y absorbers) is described through nonlinear delay differential equations. Using an optimal... 

Chatter suppression is of great importance for achieving high precision and surface quality in machining processes. A single degree of freedom model of orthogonal turning process is used to set up the nonlinear delay differential equation of motion. Tool wear effect is considered as the contact force between the workpiece and tool flank surfaces. Uncertainties in parameters of dynamic model and machining conditions are included in the model. An adaptive control strategy is applied for chatter suppression in cutting process. The force provided by a piezoactuator is the control input of the system. Results of stability analysis and adaptive control for two distinct cases of sharp and worn...