High-performance controller design and evaluation for active vibration control in boring

Document Type : Article

Authors

Department of Mechanical Engineering, Ferdowsi University of Mashhad (FUM), Mashhad, P.O. Box 9177948974, Iran.

Abstract

High quality manufactured components with fast production rate is an increasing demand of modern machine tool industry. Internal machining operations due to the large length to diameter ratio are most prone to intolerable chatter vibrations and proved to be an extremely challenging process. This paper presents a new method for proper design of direct velocity feedback (DVF) controller in order to extend boundaries of stable cutting for internal turning with minimum control effort. Control effort and active damping performance are two counteracting parameters that affect the results of active vibration control. After properly implementing the DVF active control algorithm on the internal turning setup, stable boundaries for different control gains of DVF controller are thoroughly studied. The comparison shows that although high DVF gains may considerably improve dynamic stiffness of the tool, it leads to the maximum control effort and actuator saturation and consequently process instability. The proposed gain selection method results in a significant increase in stable machining over the desired range of cutting conditions. The suggested design approach of the DVF controller can considerably improve limitations of rough machining on long over hang boring bars.

Keywords

Main Subjects


Altintas, Y., Manufacturing Automation, 2nd Edition, Cambridge University Press, New York, U.S.A, pp. 125-131 (2012). 2. Venter, G.S., Silva, L.M., Carneiro, M.B., and Silva, M.M. Passive and active strategies using embedded piezoelectric layers to improve the stability limit in turning/boring operations", International Journal of Advanced Manufacturing Technology, 89(9-12), pp. 2789-2801 (2017). 3. Munoa, J., Beudaert, X., Dombovari, Z., Altintas, Y., Budak, E., Brecher, C., and Stepan, G. Chatter suppression techniques in metal cutting", CIRP Annals - Manufacturing Technology, 65, pp. 785-808 (2016). 4. Sims, N.D. Vibration absorbers for chatter suppression: A new analytical tuning methodology", Journal of Sound & Vibration, 301, pp. 592-607 (2007). 5. Tarng, Y.S., Kao, J.Y., and Lee, E.C. Chatter suppression in turning operations with a tuned vibration absorber", Journal of Materials Processing Technology, 105, pp. 55-60 (2000). 6. Miguelez, M.H., Rubio, L., Loya, J.A., and Fernandez- Saez, J. Improvement of chatter stability in boring operations with passive vibration absorbers", International Journal of Mechanical Sciences, 52, pp. 1376- 1384 (2010). 7. Yang, Y., Munoa, J., and Altintas, Y. Optimization of multiple tuned mass dampers to suppress machine tool chatter", International Journal of Machine Tools and Manufacture, 50, pp. 834-842 (2010). 8. Liu, X., Liu, Q., Wu, S., Li, R., and Gao, H. Analysis of the vibration characteristics and adjustment method of boring bar with a variable sti_ness vibration absorber", The International Journal of Advanced Manufacturing Technology, 98, pp. 95-105 (2018). 9. Muhammad, B., Wan, M., Feng, J., and Zhang, W.H. Dynamic damping of machining vibration: a review", P. Naeemi Amini and B. Moetakef-Imani/Scientia Iranica, Transactions B: Mechanical Engineering 26 (2019) 2839{2853 2853 The International Journal of Advanced Manufacturing Technology, 89(9-12), pp. 2935-2952 (2017). 10. Tewani, S.G., Rouch, K.E., and Walcott, B.L. A study of cutting process stability of a boring bar with active dynamic absorbent", International Journal of Machine Tools and Manufacture, 35, pp. 91-108 (1995). 11. Andr_en, L. and Hakansson, L., Active Vibration Control of Boring Bar Vibration, Research Report No 2004:07, Blekinge, Sweden, pp. 5-24 (2004). 12. Matsubara, A., Maeda, M., and Yamaji, I. Vibration suppression of boring bar by piezoelectric actuators and LR circuit", CIRP Annals - Manufacturing Technology, 63(1), pp. 373-376 (2014). 13. Chen, F. Active damping of machine tools with magnetic actuators", Ph.D. Dissertation, The University of British Columbia, Vancouver, Canada (2014). 14. Pratt, J.R. and Nayfeh, A.H. Chatter control and stability analysis of a cantilever boring bar under regenerative cutting conditions", Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, 359, pp. 759-792 (2001). 15. Ganguli, A., Deraemaeker, A., and Preumont, A. Regenerative chatter reduction by active damping control", Journal of Sound and Vibration, 300, pp. 847-862 (2007). 16. Munoa, J., Mancisidor, I., Loix, N., Uriarte, L.G., Barcena, R., and Zatarain, M. Chatter suppression in ram type travelling column milling machines using a biaxial inertial actuator", CIRP Annals- Manufacturing Technology, 62, pp. 407-410 (2013). 17. Chen, F., Hanifzadegan, M., Altintas, Y., and Lu, X. Active damping of boring bar vibration with a magnetic actuator", IEEE/ASME Transactions on Mechatronics, 20, pp. 2783-2794 (2015). 18. Hayati, S., Hajaliakbari, M., Rajabi, Y., and Rasaee, S. Chatter reduction in slender boring bar via a tunable holder with variable mass and sti_ness", Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 232, pp. 2098-2108 (2018). 19. Abele, E., Haydn, M., and Grosch, T. Adaptronic approach for modular long projecting boring tools", CIRP Annals - Manufacturing Technology, 65, pp. 393-396 (2016). 20. Moetakef-Imani, B. and Yusse_an, N.Z. Dynamic simulation of boring process", International Journal of Machine Tools and Manufacture, 49, pp. 1096-1103 (2009). 21. Prosperi, F. Manufacturing of high precision mechanical components", Ph.D. Dissertation, University of Udine, Italy (2014). 22. Park, G., Bement, M.T., Hartman, D.A., Smith, R.E., and Farrar, C.R. The use of active materials for machining processes: A review", International Journal of Machine Tools and Manufacture, 47, pp. 2189-2206 (2007). 23. Chen, F., Lu, X., and Altintas, Y. A novel magnetic actuator design for active damping of machining tools", International Journal of Machine Tools and Manufacture, 85, pp. 58-69 (2014). 24. Lang, G.F. and Snyder, D. Understanding the physics of electrodynamic shaker performance", Sound and vibration, 35, pp. 24-33 (2001). 25. Preumont, A., Vibration Control of Active Structures, An Introduction, 3rd Edition, Kluwer Academic Publishers, Dordrecht, Netherlands (2011). 26. Shin, C., Hong, C., and Jeong, W.B. Active vibration control of beams using _ltered-velocity feedback controllers with moment pair actuators", Journal of Sound and Vibration, 332, pp. 2910-2922 (2013). 27. Mancisidor, I., Munoa, J., Barcena, R., Beudaert, X., and Zatarain, M. Coupled model for simulating active inertial actuators in milling processes", The International Journal of Advanced Manufacturing Technology, 77, pp. 581-595 (2015). 28. Kleinwort, R., Schweizer, M., and Zaeh, M.F. Comparison of di_erent control strategies for active damping of heavy duty milling operations", Procedia CIRP, 46, pp. 396-399 (2016).