Investigation on active vibration control to improve surface quality in precision milling process

Abstract

The tool-workpiece vibration in the precision milling process plays a pivotal role in influencing the surface quality. To solve the machining problem coming with the process vibration, the active vibration control model as well as the corresponding platform are developed, and the active vibration control algorithms are applied to reduce the relative vibrations and improve the surface quality. Firstly, the milling vibration reduction and surface quality improvement are modeled based on the active control algorithms and the system dynamic characteristics. Then, applying the different algorithm control strategies, such as PID, Fuzzy PID, BP neural network, and BP neural network PID control, the control effect is simulated and analyzed. Finally, an experimental platform is established to validate the system’s reliability. The efficiency of various active control methods is compared in terms of frequency vibration control and surface finish roughness improvement. The results indicate that under different milling parameters, the four algorithm control strategies exhibit optimal effects of 13.5%, 30.4%, 28.8%, and 40.1% respectively. These findings provide valuable insights into selecting the optimal vibration control method for precision milling.