Abstract
In order to achieve a high-quality machining process with superior productivity, it is very important to tackle the phenomenon of chatter in an effective manner. The problems like tool wear and improper surface finish affect the milling process and are caused by self-induced vibration termed as chatter. A strategy to control chatter vibration actively in the milling process is presented. The mathematical modeling of the process is carried out initially. In this paper, an innovative technique of discrete time sliding mode control (DSMC) is blended with the type-2 fuzzy logic system. The proposed active controller results in a significantly high mitigation of vibration. The DSMC is linked to the time-varying gain which is an innovative approach to mitigate chattering. The theorem is laid down which validates that the system states are bounded in the case of DSMC-type-2 fuzzy. Stability analysis is carried out using Lyapunov candidate. The nonlinearities linked with the cutting forces and damper friction are handled effectively by using the type-2 fuzzy logic system. The performance of the DSMC-type-2 fuzzy concept is compared with the discrete time PID (D-PID) and discrete time sliding mode control for validating the effectiveness of the controller. The better performance of DSMC-type-2 fuzzy over D-PID and DSMC-T1 fuzzy in the minimization of milling chatter are validated by a numerical analysis approach.
Highlights
Self-generated vibration in the machining process degrades the quality of the finished product and should be given due consideration as it is an important factor associated with manufacturing industries [1]
A type-2 fuzzy logic system performs significantly better than type-1 fuzzy logic system due to its possession of additional DOF which is known as a footprint of uncertainty [24,25]
For the validation of the significant performances of discrete time sliding mode control (DSMC)-T2 fuzzy, the results of DSMC-T2 fuzzy are compared with DSMC-T1 fuzzy and discrete time Proportional-integral derivative (PID) (D-PID)
Summary
Self-generated vibration in the machining process degrades the quality of the finished product and should be given due consideration as it is an important factor associated with manufacturing industries [1]. Liang et al [21] proposed an innovative technique to control chatter in end milling by utilizing the concept of fuzzy logic system. Ma et al [35] developed an active sliding mode control strategy to mitigate the chatter in the turning process utilizing the concept of dynamic output feedback sliding surface combined with an adaptive law for noise approximation. The numerical analysis results validate that the methodology of chatter control can be implemented effectively in the real time milling system. This can be achieved by designing and developing an AVD and placing it on the top of the milling spindle
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