Sharif Digital Repository

Chatter vibration is a major obstacle in achieveing increased machining performance. In this research, a finite element model of chip formation in a 2D milling process is used to predict the occurrence of chatter vibrations, and to investigate the effects of various machining parameters on this phenomenon. The dynamic properties of the machine tool at the tool tip are obtained based on experimental modal analysis, and are used in the model as the cutter dynamics. The model allows for the natural development of vibration as the result of the chip-tool engagement, and accounts for various phenomena that occur at the chip-tool interface ultimately leading to stable or unstable cutting. The... 

An adaptive fuzzy sliding mode control (AFSMC) for uncertain dynamic systems is presented in this paper. Chattering problem in classical sliding mode control (CSMC) is highly undesirable because it may excite unmodeled high frequency plant dynamics and leads to unforeseen instabilities. The proposed approach in this paper completely eliminates the chattering by using adaptive fuzzy system to calculate continuous control gain vector instead of discontinuous one in classical sliding mode control. Mathematical proof for the stability and the convergence of the system is also presented to show its validity theoretically. The proposed approach and the classical sliding mode control are both... 

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... 

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... 

Self-excited and forced vibrations are important topics in machining processes because their occurrence results in poor surface finish, increase in tool wear and reduction of material removal rate. In this paper, turning process is modeled as a single degree of freedom (SDOF) dynamic system including quadratic and cubic structural nonlinearities. The effect of tool flank wear, as a contact force between the workpiece and tool, is addressed vigorously. Multiple scale method is used to find the solution of the nonlinear delay-differential equation including regenerative chatter, forced excitation and tool wear. During the stability analysis, it is shown that width of cut can be considered as... 

Self-excited and forced vibrations are important topics in machining processes because their occurrence results in poor surface finish, increase in tool wear and hampers productivity. In this paper, turning process is modeled as a SDOF dynamic system including quadratic and cubic structural nonlinearities. The effect of tool flank wear, as a contact force between the work-piece and tool, is addressed vigorously. Multiple scale method is used to find the solution of the nonlinear dynamic equation including regenerative chatter, forced excitation and tool wear. It is shown that, width of cut can be considered as the bifurcation parameter of the system. Primary, super-harmonic and sub-harmonic... 

A time domain approach is used to study the cutting conditions in reaming process that leads the system to regenerative chatter vibrations. The dynamic analysis of the system includes inertia of the tool, centripetal and Coriolis terms, damping and the first mode bending of reamer. A model of cutting forces proportional to chip cross sectional area and process damping proportional to cutting speed is considered. Numerical simulation based on the Euler integration scheme is carried out to obtain time domain solution of the equation. Despite linearization in force modelling, the model is nonlinear due to the change in the tool engagement area. Another nonlinearity included in the model jumping... 

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... 

This paper addresses a simple chattering-free and finite-time convergent robust synchronization scheme for a general class of disturbed master and slave chaotic systems. Unlike traditional variable structure control schemes, the proposed controller does not directly include a switching function, and chattering is avoided. The term including switching function is the input of a low-pass filter where the filtered output is used in the controller. Also, numerical differentiation of master and slave state trajectories is not required to implement the controller. Stability of the proposed controller is established using a Lyapunov stability analysis and the finite-time convergence theories.... 

A time domain approach is used to study the cutting conditions in reaming process that leads the system to regenerative chatter vibrations. The dynamic analysis of the system includes inertia of the tool, centripetal and Coriolis terms, damping and the first mode bending of reamer. A model of cutting forces proportional to chip cross sectional area and process damping proportional to cutting speed is considered. Numerical simulation based on the Euler integration scheme is carried out to obtain time domain solution of the equation. Despite linearization in force modelling, the model is nonlinear due to the change in the tool engagement area. Another nonlinearity included in the model jumping... 

Chatter is a limiting factor in machining systems with adverse effects for workpiece surface, tool and machine life and material removal rate. Proper modelling of this phenomenon requires that the dynamic characteristics of the machining system is known. It is common to obtain the dynamic of the system by modal tests in stationary condition. However, the vibration characteristics of a machine change between its operating and resting mode. The goal of this work is to study vibrations in boring using the vibrational characteristic in operational conditions using the operating deflection shape method. In this paper, vibration characteristics of the in the boring bar is obtained by both modal... 

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... 

Chatter vibration is a major obstacle in achieving high performance machining. In order to present a realistic model of chatter vibration, in this research, a finite element simulation of orthogonal chip formation combined with a 2D model of machine tool dynamics is developed. The proposed approach has the ability to incorporate various, mostly nonlinear, phenomena affecting chatter occurrence. The dynamic allows the tool to vibrate as a result of chip load variation leading to chatter. The 2DOF model makes it possible to observe the occurrence of model coupling phenomenon, in addition to the regeneration of waviness mechanism. The investigation of mode-coupling and regeneration phenomena in... 

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...