Adaptive inverse control of chatter vibrations in internal turning operations
TL;DR: The obtained results suggest that the practical application of adaptive inverse control algorithms for chatter rejection can be extended to other machining processes as well.
About: This article is published in Mechanical Systems and Signal Processing.The article was published on 2019-08-15. It has received 25 citations till now. The article focuses on the topics: Chatter mark & Active vibration control.
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TL;DR: A critical review of chatter is presented, focusing on regenerative chatter and mode coupling chatter, and four directions for future research are presented, including integrating the chatter prediction, detection and suppression units into a smart machine tool or smart spindle.
170 citations
TL;DR: Despite their numerous advantages in terms of efficiency, time saving, and cost, the current situation of sensors used in the industry is not a sufficient level due to the investment cost and its increase with additional signal acquisition hardware and software equipment.
Abstract: Sensors are the main equipment of the data-based enterprises for diagnosis of the health of system. Offering time- or frequency-dependent systemic information provides prognosis with the help of early-warning system using intelligent signal processing systems. Therefore, a chain of data-based information improves the efficiency especially focusing on the determination of remaining useful life of a machine or tool. A broad utilization of sensors in machining processes and artificial intelligence–supported data analysis and signal processing systems are prominent technological tools in the way of Industry 4.0. Therefore, this paper outlines the state of the art of the mentioned systems encountered in the open literature. As a result, existing studies using sensor systems including signal processing facilities in machining processes provide important contribution for error minimization and productivity maximization. However, there is a need for improved adaptive control systems for faster convergence and physical intervention in case of possible problems and failures. On the other hand, sensor fusion is an innovative new technology that makes decisions using multi-sensor information to determine tool status and predict system stability. It is currently not a fully accepted and practiced method. In a nutshell, despite their numerous advantages in terms of efficiency, time saving, and cost, the current situation of sensors used in the industry is not a sufficient level due to the investment cost and its increase with additional signal acquisition hardware and software equipment. Therefore, more studies that can contribute to the literature are needed.
42 citations
TL;DR: Experimental results illustrate that the milling chatter can be well suppressed with the presented method and system, which shows advantages of robustness and practicality.
37 citations
TL;DR: A novel active control method based on piezoelectric actuators embedded to the tool holder is proposed in this work, and the results show that not only the chatter is effectively suppressed, but also the control energy of the actuators is significantly reduced.
25 citations
TL;DR: In this article, the authors provide a valuable guide for researchers to assist in identification and application of the best possible condition monitoring method for machining processes and rotary components, which is intended as a valuable information for researchers.
Abstract: Condition monitoring is a significant requirement for ensuring safe and reliable working of machining processes and rotary components. Recent developments in digital signal processing techniques along with emergence of miniature sensors and high-speed data acquisition devices furnish a peculiar opportunity for the development and implementation of effective, in-situ, non-intrusive condition monitoring methods for a broad range of machining processes and rotary components. The selection of most appropriate signal processing technique, best suited for a particular application, is a major challenge in the field of condition monitoring, especially when working in a competitive industrial environment. This problem can only be solved if one has a thorough understanding of various aspects such as which parameter to be monitored, aim of monitoring, processing limitations and possible future scope of such monitoring method. Signal processing methods applicable to machining processes and rotary components have been investigated in relation to the parameters monitored, purpose of monitoring and future scope for that method. Limitations of such processing methods have also been reviewed to make the reader aware of disadvantages in using a particular signal processing method. This paper is intended as a valuable guide for researchers to assist in identification and application of the best possible condition monitoring method for machining processes and rotary components.
19 citations
References
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Book•
13 Apr 2000TL;DR: In this paper, the authors discuss the application of metal cutting to manufacturing problems, including the design of real-time trajectory generation and interpolation algorithms, and CNC-oriented error analysis.
Abstract: Metal cutting is a widely used method of producing manufactured products. The technology of metal cutting has advanced considerably along with new materials, computers, and sensors. This new edition treats the scientific principles of metal cutting and their practical application to manufacturing problems. It begins with metal cutting mechanics, principles of vibration, and experimental modal analysis applied to solving shop floor problems. Notable is the in-depth coverage of chatter vibrations, a problem experienced daily by manufacturing engineers. The essential topics of programming, design, and automation of CNC (computer numerical control) machine tools, NC (numerical control) programming, and CAD/CAM technology are discussed. The text also covers the selection of drive actuators, feedback sensors, modeling and control of feed drives, the design of real time trajectory generation and interpolation algorithms, and CNC-oriented error analysis in detail. Each chapter includes examples drawn from industry, design projects, and homework problems. This book is ideal for advanced undergraduate and graduate students, as well as practicing engineers.
1,854 citations
01 Jun 1999
TL;DR: The basic adaptive algorithm for ANC is developed and analyzed based on single-channel broad-band feedforward control, then modified for narrow-bandFeedforward and adaptive feedback control, which are expanded to multiple-channel cases.
Abstract: Active noise control (ANC) is achieved by introducing a cancelling "antinoise" wave through an appropriate array of secondary sources. These secondary sources are interconnected through an electronic system using a specific signal processing algorithm for the particular cancellation scheme. ANC has application to a wide variety of problems in manufacturing, industrial operations, and consumer products. The emphasis of this paper is on the practical aspects of ANC systems in terms of adaptive signal processing and digital signal processing (DSP) implementation for real-world applications. In this paper, the basic adaptive algorithm for ANC is developed and analyzed based on single-channel broad-band feedforward control. This algorithm is then modified for narrow-band feedforward and adaptive feedback control. In turn, these single-channel ANC algorithms are expanded to multiple-channel cases. Various online secondary-path modeling techniques and special adaptive algorithms, such as lattice, frequency-domain, subband, and recursive-least-squares, are also introduced. Applications of these techniques to actual problems are highlighted by several examples.
1,254 citations
Book•
06 Feb 1991
TL;DR: In this article, Figliola and Beasley first discuss the basics of measurement, analogue and digital data acquisition systems and signal processing, the statistics of measurement and the analysis of error and uncertainty.
Abstract: The assignment of numerical values to physical quantities underlies all quantitative statements in engineering and the physical sciences. This assignment is achieved by the process of measurement. The physical quantity being measured and the precision required in the numerical value determines the instrumentation to be used. The design of a measurement system therefore involves the analysis of the attribute to be measured, the means available for its detection and the verification that the measurement system performs as intended and can achieve the desired accuracy and precision. In this book Figliola and Beasley first discuss in general terms the basics of measurement, analogue and digital data acquisition systems and signal processing, the statistics of measurement and the analysis of error and uncertainty. In successive chapters they concentrate on the instruments and their physical basis in the areas of electricity, temperature, fluid flow, elastic strain and mechanics (displacement, motion, force and power). The coverage is directed towards measurements in various branches of engineering, with numerous worked examples and problems for students (approximately 30 to 40) at the end of each chapter. Since it is an American engineering text, the book uses both SI and English units. Unfortunately, the text is flawed by numerous errors. Some of the more egregious are that in chapter 1, `dimension' is used in place of `unit', the definitions given for the ampere and the ohm are in terms of `international' units that were abandoned in 1948 and derived units are expressed, for example, as `' in place of the standard forms (SI, ISO, ANSI) of `' or `'. There are furthermore numerous minor numerical errors and inconsistencies. One of the more serious flaws is the failure to distinguish between bias errors and uncertainty due to bias in the discussion of chapter 5. There is also a misuse of the student in the evaluation of uncertainty (although this error is not exclusively Figliola and Beasley's, since it occurs in ANSI documents on fluid flow measurement). Given the estimate for variance, with degrees of freedom, an uncertainty interval at confidence level p is properly , while the uncertainty for a combined quantity is where is evaluated from the Welch - Satterthwaite expression In spite of its shortcomings, the book collects a great deal of material in one place and, in the hands of a careful instructor who is aware of its flaws, could be useful as a supplementary text on measurement. E Richard Cohen
913 citations
Book•
26 Sep 2000
TL;DR: Signal Processing for Active Control as mentioned in this paper presents a unified approach to techniques that are used in the analysis and implementation of different active control systems and includes practical examples at the end of each chapter to illustrate the use of various approaches.
Abstract: Signal Processing for Active Control sets out the signal processing and automatic control techniques that are used in the analysis and implementation of active systems for the control of sound and vibration. After reviewing the performance limitations introduced by physical aspects of active control, Stephen Elliott presents the calculation of the optimal performance and the implementation of adaptive real time controllers for a wide variety of active control systems. Active sound and vibration control are technologically important problems with many applications. 'Active control' means controlling disturbance by superimposing a second disturbance on the original source of disturbance. Put simply, initial noise + other specially-generated noise or vibration = silence [or controlled noise]. This book presents a unified approach to techniques that are used in the analysis and implementation of different control systems. It includes practical examples at the end of each chapter to illustrate the use of various approaches. This book is intended for researchers, engineers, and students in the field of acoustics, active control, signal processing, and electrical engineering.
904 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