Abstract
Abstract A typical boring bar is a metal cutting tool with large overhang ratio, due to which it is characterized by low dynamic stiffness. Therefore, during cutting process, it is susceptible to cutting instability, known as machine tool chatter. In this paper, the use of an active dynamic absorber to actively control machine tool chatter in a boring bar is studied. An active dynamic absorber is designed such that it can be easily assembled with a commercially available steel boring bar. A piezoelectric pusher is used as the actuator for the active dynamic absorber. The dynamic equations of the boring bar with active dynamic absorber are calculated from experimentally obtained frequency response functions of the system. Optimal control theory is applied to the dynamic equations to calculate state variable feedback parameters. The state variable feedback is implemented using a Digital Signal Processing (DSP) chip. Cutting tests were performed with this setup for different cutting conditions, and for different overhangs of the boring bar. Stable cutting operations were performed using the boring bar with active dynamic absorber, for length to diameter (L/D) ratio upto 9.
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