Active chatter suppression with displacement-only measurement in turning process
TL;DR: In this paper, an active sliding mode controller, which employs a dynamic output feedback sliding surface for the unmatched condition and an adaptive law for disturbance estimation, is designed, analyzed, and validated for chatter suppression in turning process.
About: This article is published in Journal of Sound and Vibration.The article was published on 2017-08-04. It has received 34 citations till now. The article focuses on the topics: Sliding mode control & Control theory.
Citations
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TL;DR: The results of milling experiment show that the proposed chatter identification method can recognize early milling chatter effectively and a support vector machine chatter identification model is obtained based on the multi-indicators.
56 citations
01 May 2019-Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology
TL;DR: In this paper, a proportional-derivative controller was proposed to suppress milling chatter vibration and improve surface finish of a milling spindle with a noncontact electromagnetic actuator with two degrees of freedom.
Abstract: Self-excited vibration, widely referred to as chatter, has always been a limitation and challenge in machining. To suppress milling chatter vibration and improve surface finishes, a novel spindle system is proposed in this study. A noncontact electromagnetic actuator with two degrees of freedom is developed and integrated into the designed spindle system compactly. A differential driving mode is utilized for the electromagnetic actuator to obtain a linear output of actuator force, making the actuator more applicable for vibration control. Displacement sensors mounted near the actuator measure the vibration of the rotating spindle shaft and provide feedback signals for the developed proportional-derivative controller. The active damping performance of the designed spindle system with an integrated electromagnetic actuator, in both x and y directions, is also validated with impact tests and milling experiments, and a maximum increase (by factors of 3.67 and 2.89 in x and y directions, respectively) of dynamic stiffness at the first modal frequency is obtained. Milling experiment results with and without active damping also illustrate that milling chatter vibration has been well damped actively with the developed spindle system.
37 citations
TL;DR: In this article, the main efforts from the scientific literature to predict stability and to avoid chatter with special emphasis on turning systems are summarized and compared with the main active and passive techniques.
Abstract: The general trend towards lightweight components and stronger but difficult to machine materials leads to a higher probability of vibrations in machining systems. Amongst them, chatter vibrations are an old enemy for machinists with the most dramatic cases resulting in machine-tool failure, accelerated tool wear and tool breakage or part rejection due to unacceptable surface finish. To avoid vibrations, process designers tend to command conservative parameters limiting productivity. Among the different machining processes, turning is responsible of a great amount of the chip volume removed worldwide. This paper reports some of the main efforts from the scientific literature to predict stability and to avoid chatter with special emphasis on turning systems. There are different techniques and approaches to reduce and to avoid chatter effects. The objective of the paper is to summarize the current state of research in this hot topic, particularly (1) the mechanistic, analytical, and numerical methods for stability prediction in turning; (2) the available techniques for chatter detection and control; (3) the main active and passive techniques.
28 citations
TL;DR: Theoretical analyses, numerical simulations, and experimental evaluation on a lathe demonstrate that chatter in thin plate turning can be effectively attenuated with the proposed active control method.
Abstract: This paper presents an active control method, consisting of an adaptive sliding-mode controller (ASMC) and a displacement field reconstruction (DFR) method, for chatter suppression in turning of thin-walled workpieces (such as compressor disks and casings in aircraft engines) where low workpiece stiffness renders machining with potential regenerative chatter. Due to the presence of multi-modal dynamics, variant modal parameters, and measurement difficulties, active chatter control of thin plate turning has been challenging. Unlike existing controls based on a lumped-parameter single degree-of-freedom cutting model, a distributed-parameter dynamic model of a rotating thin plate with multiple vibration modes is used to analyze the machining stability with the designed controller. Moreover, model parameters of the plate are not needed to construct the controller. The DFR is employed to capture the plate dynamic behavior for feedback to the ASMC during turning, overcoming the long existing difficulties to measure plate vibration at the cutting point. A fast tool servo is utilized in the control implementation. Theoretical analyses, numerical simulations, and experimental evaluation on a lathe demonstrate that chatter in thin plate turning can be effectively attenuated with the proposed active control method.
19 citations
Cites background from "Active chatter suppression with dis..."
...[15] presented a dynamic output feedback controller for chatter suppression in turning processes, where only displacement mea-...
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TL;DR: In this paper, the fractal feature of the signal is extracted by structure function method (SFM) for the first time, which solves the problem that the features are easily affected by process parameters.
Abstract: Data-driven chatter detection techniques avoid complex physical modeling and provide the basis for industrial applications of cutting process monitoring. Among them, feature extraction is the key step of chatter detection, which can compensate for the accuracy disadvantage of machine learning algorithms to some extent if the extracted features are highly correlated with the milling condition. However, the classification accuracy of the current feature extraction methods is not satisfactory, and a combination of multiple features is required to identify the chatter. This limits the development of unsupervised machine learning algorithms for chattering detection, which further affects the application in practical processing. In this paper, the fractal feature of the signal is extracted by structure function method (SFM) for the first time, which solves the problem that the features are easily affected by process parameters. Milling chatter is identified based on k-means algorithm, which avoids the complex process of training model, and the judgment method of milling chatter is also discussed. The proposed method can achieve 94.4% identification accuracy by using only one single signal feature, which is better than other feature extraction methods, and even better than some supervised machine learning algorithms. Moreover, experiments show that chatter will affect the distribution of cutting bending moment, and it is not reliable to monitor tool wear through the polar plot of the bending moment. This provides a theoretical basis for the application of unsupervised machine learning algorithms in chatter detection.
17 citations
References
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Book•
01 Jan 1995
TL;DR: In this paper, the focus is on adaptive nonlinear control results introduced with the new recursive design methodology -adaptive backstepping, and basic tools for nonadaptive BackStepping design with state and output feedbacks.
Abstract: From the Publisher:
Using a pedagogical style along with detailed proofs and illustrative examples, this book opens a view to the largely unexplored area of nonlinear systems with uncertainties. The focus is on adaptive nonlinear control results introduced with the new recursive design methodology--adaptive backstepping. Describes basic tools for nonadaptive backstepping design with state and output feedbacks.
6,923 citations
TL;DR: In this article, a class of state feedback controls is proposed in order to guarantee uniform ultimate boundedness of every system response within an arbitrarily small neighborhood of the zero state, and these feedback controls are continuous functions of the state.
Abstract: We consider a dynamic system containing uncertain elements. Only the set of possible values of these uncertainties is known. Based on this information a class of state feedback controls is proposed in order to guarantee uniform ultimate boundedness of every system response within an arbitrarily small neighborhood of the zero state. These feedback controls are continuous functions of the state.
1,546 citations
TL;DR: A review of the state of research on the chatter problem and classifications the existing methods developed to ensure stable cutting into those that use the lobbing effect, out-of-process or in-process, and those that, passively or actively, modify the system behavior as mentioned in this paper.
Abstract: Chatter is a self-excited vibration that can occur during machining operations and become a common limitation to productivity and part quality. For this reason, it has been a topic of industrial and academic interest in the manufacturing sector for many years. A great deal of research has been carried out since the late 1950s to solve the chatter problem. Researchers have studied how to detect, identify, avoid, prevent, reduce, control, or suppress chatter. This paper reviews the state of research on the chatter problem and classifies the existing methods developed to ensure stable cutting into those that use the lobbing effect, out-of-process or in-process, and those that, passively or actively, modify the system behaviour.
790 citations
TL;DR: A critical review of the different chatter suppression techniques can be found in this paper, where the evolution of each technique is described remarking the most important milestones in research and the corresponding industrial application.
454 citations
TL;DR: A full-discretization method based on the direct integration scheme for prediction of milling stability based on Floquet theory that has high computational efficiency without loss of any numerical precision is presented.
Abstract: This paper presents a full-discretization method based on the direct integration scheme for prediction of milling stability. The fundamental mathematical model of the dynamic milling process considering the regenerative effect is expressed as a linear time periodic system with a single discrete time delay, and the response of the system is calculated via the direct integration scheme with the help of discretizing the time period. Then, the Duhamel term of the response is solved using the full-discretization method. In each small time interval, the involved system state, time-periodic and time delay items are simultaneously approximated by means of linear interpolation. After obtaining the discrete map of the state transition on one time interval, a closed form expression for the transition matrix of the system is constructed. The milling stability is then predicted based on Floquet theory. The effectiveness of the algorithm is demonstrated by using the benchmark examples for one and two degrees of freedom milling models. It is shown that the proposed method has high computational efficiency without loss of any numerical precision. The code of the algorithm is also attached in the appendix.
435 citations