Chatter suppression for milling of thin-walled workpieces based on active modal control

Abstract

Owing to the low stiffness of workpiece, chatter easily occurs in milling of thin-walled structures, which may cause poor surface quality and uncontrolled machining accuracy. For suppressing milling chatter of thin-walled workpieces, this paper presents an active control method with a piezoelectric patch actuator. As a flexible body, thin-walled workpieces have more than one modals participating in milling vibration, and its dynamic characteristics vary with tool position. This paper establishes dynamic model of the thin-walled workpiece with a semi-analytical method. Considering three order modals of workpiece, actuator position is optimized and active controller is designed. The varying dynamic characteristics of workpiece are overcome by designing controller with the parameters on the maximum vibration position to stabilize the whole process. Experiments verify the necessity of considering more than one modals of workpiece in active control through various chatter characteristics dominant by different modals. With the designed control method, the stable cutting depth improves from 0.2 mm to 1 mm.