Robust Active Chatter Control in the High-Speed Milling Process

Niels J. M. van Dijk, Nathan van de Wouw, Ed J. J. Doppenberg, Han A. J. Oosterling, Henk Nijmeijer
2012 IEEE Transactions on Control Systems Technology  
Chatter is an instability phenomenon in machining processes which limits productivity and results in inferior workpiece quality, noise and rapid tool wear. The increasing demand for productivity in the manufacturing community motivates the development of an active control strategy to shape the chatter stability boundary of manufacturing processes. In this work a control methodology for the high-speed milling process is developed that alters the chatter stability boundary such that the area of
more » ... atterfree operating points is increased and a higher productivity can be attained. The methodology developed in this paper is based on a robust control approach using -synthesis. Hereto, the most important process parameters (depth of cut and spindle speed) are treated as uncertainties to guarantee the robust stability (i.e., no chatter) in an a priori specified range of these process parame- ters. Effectiveness of the proposed methodology is demonstrated by means of illustrative examples. Index Terms-Active control, delay systems, high-speed milling, machining chatter, magnetic bearings, robust controller synthesis. NOMENCLATURE Axial depth of cut-mm. Constant for selecting controller input. Tooth passing frequency-Hz. Actuator/tooltip force-N. Spindle-actuator transfer function matrix. Averaged cutting force matrix-N/m . Controller output-A. Controller transfer function matrix-A/m. Spindle speed-rpm. Generalized plant.
doi:10.1109/tcst.2011.2157160 fatcat:7kuhll4hlzfkre5vbipuhqzxoy