Iranian Journal of Mechanical Engineering Transactions of ISME

Iranian Journal of Mechanical Engineering Transactions of ISME

Boring bar chatter control using a novel adaptive direct velocity feedback controller

Authors
Mohsen Fallah 1
Behnam Moetakef-Imani 2
1 CAD/CAM Laboratory, Mechanical Engineering Department, Ferdowsi University of Mashhad, Mashhad, Iran,
2 Mechanical Engineering Department, Engineering Faculty, Ferdowsi University of Mashhad, Mashhad, Iran,
10.30506/ijmep.2020.106431.1565
Abstract
In this paper, a new adaptive control system is presented for suppression of boring bar chatter
in internal turning process. The vibration control system consists of electromagnetic actuator,
boring bar, accelerometer and a novel adaptive control algorithm. The controller gain is
adaptively adjusted according to the operating condition of actuator and the level of boring
bar vibrations so that the consumed actuator power always remain proportional to the
intensity of chatter vibrations due to the cutting process.
As a result, the gain adaptation algorithm is indirectly developed by using the dynamic
characteristics of the actuator-boring bar assembly. Firstly, the tunable parameters of adaptive
controller are optimally identified by conducting impact tests. Secondly, the performance of
adaptive controller is investigated during the internal turning of Aluminum alloy 6063-T6.
The presented adaptive control system can improve the dynamic stiffness of boring bar as
well as the critical limiting depth of cut on stability chart by at least 10 folds. Due to the
optimal performance of the adaptive controller, the dominant magnitude of boring bar’s
power spectral density is successfully attenuated up to 78 dBs. Also, the roughness of cut
surface is reduced from above 40 micrometers in control-off cutting test to below 5
micrometers in control-on test. Moreover, the actuator cost is considerably reduced for the
adaptive controller, in comparison to the optimal constant-gain integral controller. As a result,
by using the proposed adaptive control algorithm, a smaller electromagnetic actuator with
lower power capacity can be used for chatter suppression in the same cutting conditions.
Keywords
Active Boring Bar
Active Vibration Control
Adaptive Control Algorithm
Stability Improvement
Chatter Suppression

Subjects

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  • Receive Date 17 April 2019
  • Revise Date 09 August 2019
  • Accept Date 08 November 2020