Spindle speed variation and adaptive force regulation to suppress regenerative chatter in the turning process

Abstract

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, two control strategies are developed to suppress chatter vibration in the turning process including a worn tool. In the first stage, a sinusoidal spindle speed variation around the mean speed is modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. In the second stage, to improve the response of the system which is associated with small ripples under the steady state condition, an adaptive controller is designed. In this stage, the provided external force (e.g., by a piezo-actuator) is the input variable. Results are provided for each control strategy. It is shown that if both control approaches are applied simultaneously, chatter vibration is suppressed in less time without any ripples at the steady state condition.