Abstract
The problem of chatter vibration is associated with adverse consequences that often lead to tool impairment and poor surface finished in a workpiece, and thus, controlling or suppressing chatter vibrations is of great significance to improve machining quality. In this paper, a workpiece and an actuator dynamics are considered in modeling and controller design. A proportional-integral controller (PI) is presented to control and actively damp the chatter vibration of a workpiece in the milling process. The controller is chosen on the basis of its highly stable output and a smaller amount of steady-state error. The controller is realized using analog operational amplifier circuit. The work has contributed to planning a novel approach that addresses the problem of chatter vibration in spite of technical hitches in modeling and controller design. The method can also lead to considerable reduction in vibrations and can be beneficial in industries in term of cost reduction and energy saving. The application of this method is verified using active damping device actuator (ADD) in the milling of steel.
Highlights
The modification of metal part into desired shape and size, for a different purpose in industries, are produced by milling
The problem of chatter vibration is associated with adverse consequences that often lead to tool impairment and poor surface finished in a workpiece, and controlling or suppressing chatter vibrations is of great significance to improve machining quality
The work has contributed to planning a novel approach that addresses the problem of chatter vibration in spite of technical hitches in modeling and controller design
Summary
The modification of metal part into desired shape and size, for a different purpose in industries, are produced by milling Such process can certainly be disturbed by chatter vibration, which leads to negative effects ranging from the poor surface finish, reduced work quality and high production cost to machine impairment [1, 2]. Tsai et al [16] proposed acoustic signal feedback and spindle speed compensation for intelligent control application to avoid chatter vibration in milling process. Information describing the operational amplifier circuit and its application in filter, amplification, and control capabilities were explained [37,38,39] This is the major approach to resolve chatter vibration problem in the milling process via the operational amplifier circuit. Encouraged by the above consideration, a proportional-integral controller is proposed to suppress the chatter vibrations in the milling process. This work contributes to minimizing chatter vibration and its negative consequences
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