Using a combination of vibration absorber and a classical active controller to suppress the chatter vibration and increase the stability in turning process

2021 ◽  
Author(s):  
Yashar Ebadi ◽  
Hamed Moradi
Keyword(s):  
Vibration Absorber ◽  
Chatter Vibration ◽  
Turning Process ◽  
The Stability

Turning Dynamics: Part 1 — Experimental Analysis

2012 ◽  
Author(s):  
Eric B. Halfmann ◽  
C. Steve Suh ◽  
N. P. Hung
Keyword(s):  
Instantaneous Frequency ◽  
Period Doubling ◽  
Displacement Sensor ◽  
Laser Displacement Sensor ◽  
Turning Process ◽  
Time Frequency ◽  
Spectral Components ◽  
Tool Vibrations ◽  
Exact Moment ◽  
The Stability

The workpiece and tool vibrations in a lathe are experimentally studied to establish improved understanding of cutting dynamics that would support efforts in exceeding the current limits of the turning process. A Keyence laser displacement sensor is employed to monitor the workpiece and tool vibrations during chatter-free and chatter cutting. A procedure is developed that utilizes instantaneous frequency (IF) to identify the modes related to measurement noise and those innate of the cutting process. Instantaneous frequency is shown to thoroughly characterize the underlying turning dynamics and identify the exact moment in time when chatter fully developed. That IF provides the needed resolution for identifying the onset of chatter suggests that the stability of the process should be monitored in the time-frequency domain to effectively detect and characterize machining instability. It is determined that for the cutting tests performed chatters of the workpiece and tool are associated with the changing of the spectral components and more specifically period-doubling bifurcation. The analysis presented provides a view of the underlying dynamics of the lathe process which has not been experimentally observed before.

Analytical and experimental stability analysis of AU4G1 thin-walled tubular workpieces in turning process

2020 ◽  
Vol 234 (6-7) ◽  
pp. 1007-1018 ◽  
Author(s):  
Zied Sahraoui ◽  
Kamel Mehdi ◽  
Moez Ben-Jaber
Keyword(s):  
Stability Analysis ◽  
Feed Rate ◽  
Experimental Studies ◽  
Rake Angle ◽  
Machining Process ◽  
Structural Damping ◽  
Turning Process ◽  
Process Stability ◽  
Thin Walled ◽  
The Stability

The development of the manufacturing-based industries is principally due to the improvement of various machining operations. Experimental studies are important in researches, and their results are also considered useful by the manufacturing industries with their aim to increase quality and productivity. Turning is one of the principal machining processes, and it has been studied since the 20th century in order to prevent machining problems. Chatter or self-excited vibrations represent an important problem and generate the most negative effects on the machined workpiece. To study this cutting process problem, various models were developed to predict stable and unstable cutting conditions. Stability analysis using lobes diagrams became useful to classify stable and unstable conditions. The purpose of this study is to analyze a turning process stability using an analytical model, with three degrees of freedoms, supported and validated with experimental tests results during roughing operations conducted on AU4G1 thin-walled tubular workpieces. The effects of the tubular workpiece thickness, the feed rate and the tool rake angle on the machining process stability will be presented. In addition, the effect of an additional structural damping, mounted inside the tubular workpiece, on the machining process stability will be also studied. It is found that the machining stability process is affected by the tubular workpiece thickness, the feed rate and the tool rake angle. The additional structural damping increases the stability of the machining process and reduces considerably the workpiece vibrations amplitudes. The experimental results highlight that the dynamic behavior of turning process is governed by large radial deformations of the thin-walled workpieces. The influence of this behavior on the stability of the machining process is assumed to be preponderant.

Stability analysis in machining process by using adaptive closed-loop feedback control system in turning process

2020 ◽  
pp. 107754632095261
Author(s):  
Kashfull Orra ◽  
Sounak K Choudhury
Keyword(s):  
Control System ◽  
Feedback Control ◽  
Closed Loop ◽  
Machining Process ◽  
Feedback Control System ◽  
Turning Process ◽  
Tool Vibration ◽  
Loop Feedback ◽  
Closed Loop Feedback ◽  
The Stability

The study presents model-based mechanism of nonlinear cutting tool vibration in turning process and the strategy of improving cutting process stability by suppressing machine tool vibration. The approach used is based on the closed-loop feedback control system with the help of electro–magneto–rheological damper. A machine tool vibration signal generated by an accelerometer is fed back to the coil of a damper after suitable amplification. The damper, attached under the tool holder, generates counter forces to suppress the vibration after being excited by the signal in terms of current. The study also discusses the use of transfer function approach for the development of a mathematical model and adaptively controlling the process dynamics of the turning process. The purpose of developing such mechanism is to stabilize the machining process with respect to the dynamic uncut chip thickness responsible for the type-II regenerative effect. The state-space model used in this study successfully checked the adequacy of the model through controllability and observability matrices. The eigenvalue and eigenvector have confirmed the stability of the system more accurately. The characteristic of the stability lobe chart is discussed for the present model-based mechanism.

Using a Vibration Absorber to Suppress Chatter Vibration in Turning Process With a Worn Tool

2009 ◽  
Author(s):  
Hamed Moradi ◽  
Firooz Bakhtiari-Nejad ◽  
Mohammad R. Movahhedi
Keyword(s):  
Transmission Lines ◽  
Gas Turbines ◽  
Block Diagram ◽  
Vibration Absorber ◽  
Vibration Absorbers ◽  
Turning Process ◽  
Electrical Transmission ◽  
Chatter Suppression ◽  
Orthogonal Turning ◽  
Dynamic Vibration Absorbers

Dynamic vibration absorbers are used as semi-active controllers to reduce the undesirable vibrations in many applications such as electrical transmission lines, helicopters, gas turbines, engines, bridges and etc. One type of these absorbers is tunable vibration absorber (TVA). In this paper, regenerative chatter in an orthogonal turning process is suppressed using a (TVA). It is shown that TVA can modify the frequency response function of the cutting tool so as to improve cutting stability in turning process. In addition, tool wear is an important factor which works as a positive damping and helps the chatter suppression beside exertion of the TVA. Finally, using the SIMULINK Toolbox of MATLAB, the analog simulated block diagram of the problem is developed. The advantage of this simulation is that, one can analyze the effect of other types of excitations such as step, ramp, etc on the absorbed system.

Experimental Study of the Dynamic Behavior of Thin-Walled Tubular Workpieces in Turning Cutting Process

2020 ◽  
pp. 1-19
Author(s):  
Zied Sahraoui ◽  
Kamel Mehdi ◽  
Moez Ben Jaber
Keyword(s):  
Dynamic Behavior ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Cutting Process ◽  
Machining Process ◽  
Structural Damping ◽  
Turning Process ◽  
Manufactured Products ◽  
Thin Walled ◽  
The Stability

Nowadays, industrialists, especially those in the automobile and aeronautical transport fields, seek to lighten the weight of different product components by developing new materials lighter than those usually used or by replacing some massive parts with thin-walled hollow parts. This lightening operation is carried out in order to reduce the energy consumption of the manufactured products while guaranteeing optimal mechanical properties of the components and increasing quality and productivity. To achieve these objectives, some research centers have focused their work on the development and characterization of new light materials and some other centers have focused their work on the analysis and understanding of the encountered problems during the machining operation of thin-walled parts. Indeed, various studies have shown that the machining process of thin-walled parts differs from that of rigid parts. This difference comes from the dynamic behavior of the thin-walled parts which is different from that of the massive parts. Therefore, the purpose of this paper is to first highlight some of these problems through the measurement and analysis of the cutting forces and vibrations of tubular parts with different thicknesses in AU4G1T351 aluminum alloy during the turning process. The experimental results highlight that the dynamic behavior of turning process is governed by large radial deformations of the thin-walled workpieces and the influence of this behavior on the variations of the chip thickness and cutting forces is assumed to be preponderant. The second objective is to provide manufacturers with a practical solution to the encountered vibration problems by improving the structural damping of thin-walled parts by additional damping. It is found that the additional structural damping increases the stability of the cutting process and reduces considerably the vibrations amplitudes.

scholarly journals Digital control of cable vibration with time delay

2020 ◽  
Author(s):  
László E. Kollár
Keyword(s):  
Time Delay ◽  
Active Control ◽  
Digital Control ◽  
Vibration Amplitude ◽  
Excitation Frequency ◽  
Vibration Absorber ◽  
Wind Effect ◽  
Cable Vibration ◽  
The Stability ◽  
Short Time

Abstract A simplified model for active control of vibration of a suspended cable is proposed. The model is constructed so that it considers the dynamic characteristics of the cable at the location where a vibration absorber is attached together with the absorber itself. The control is applicable for attenuating high-frequency, low-amplitude cable vibration due to periodic excitation that may model the wind effect. The methodology to choose control parameters is based on the dynamics of the vibration absorber and the stability analysis of the controlled system. The model takes into account the time delay that is always present in digital control due to sampling. Results reveal that the application of active control reduces vibration amplitude significantly provided that samples are taken in short time intervals. Increasing time delay reduces the effects of control and above a critical value, the vibration amplitude becomes even greater than without control. The importance of time delay grows with increasing excitation frequency, which means a limitation of the application of the control methodology developed. This limitation concerns the highest excitation frequencies.

scholarly journals Evaluation of the Autoparametric Pendulum Vibration Absorber for a Duffing System

2008 ◽  
Vol 15 (3-4) ◽  
pp. 355-368 ◽  
Author(s):  
Benjamın Vazquez-Gonzalez ◽  
Gerardo Silva-Navarro
Keyword(s):  
Frequency Response ◽  
Fixed Points ◽  
Multiple Scales ◽  
Coupled System ◽  
Vibration Absorber ◽  
Primary System ◽  
Duffing System ◽  
Approximate Frequency ◽  
The Stability ◽  
Cubic Stiffness

In this work we study the frequency and dynamic response of a damped Duffing system attached to a parametrically excited pendulum vibration absorber. The multiple scales method is applied to get the autoparametric resonance conditions and the results are compared with a similar application of a pendulum absorber for a linear primary system. The approximate frequency analysis reveals that the nonlinear dynamics of the externally excited system are suppressed by the pendulum absorber and, under this condition, the primary Duffing system yields a time response almost equivalent to that obtained for a linear primary system, although the absorber frequency response is drastically modified and affected by the cubic stiffness, thus modifying the jumps defined by the fixed points. In the absorber frequency response can be appreciated a good absorption capability for certain ranges of nonlinear stiffness and the internal coupling is maintained by the existing damping between the pendulum and the primary system. Moreover, the stability of the coupled system is also affected by some extra fixed points introduced by the cubic stiffness, which is illustrated with several amplitude-force responses. Some numerical simulations of the approximate frequency responses and dynamic behavior are performed to show the steady-state and transient responses.

Dynamic Behavior of a Thin-Walled Cylindrical Workpiece During the Turning Process, Part 1: Cutting Process Simulation

2002 ◽  
Vol 124 (3) ◽  
pp. 562-568 ◽  
Author(s):  
K. Mehdi ◽  
J.-F. Rigal ◽  
D. Play
Keyword(s):  
Dynamic Behavior ◽  
Process Simulation ◽  
Point Of View ◽  
Cutting Process ◽  
Natural Phenomenon ◽  
Chatter Vibration ◽  
Turning Process ◽  
Chatter Vibrations ◽  
Cylindrical Workpiece ◽  
Thin Walled

From a practical point of view, in machining applications, chatter vibration constitutes a major problem during the cutting process. It is becoming increasingly difficult to suppress chatter during cutting at high speeds. Many investigators have regarded chatter vibrations as a “natural” phenomenon during the cutting process and a part of the process itself. In classical machining operations with thick-walled workpieces chatter vibrations occur when the cutting depth exceeds stability limits dependent on the machine tool. On the other hand, in the case of thin-walled cylindrical workpieces, chatter vibration problems are not so simple to formulate. The main purpose of this study is to qualify the dynamic behavior of a thin-walled workpiece during the turning process. It contains two parts: the cutting process simulation and the definition of experimental stability criteria. In the first part, a numerical model, which simulates the turning process of thin-walled cylindrical workpieces, is proposed. This model also permits obtaining workpiece responses to excitation generated by cutting forces. Finally, the stability of the process is discussed.

Stability prediction of milling process with variable pitch and variable helix cutters

2013 ◽  
Vol 228 (2) ◽  
pp. 281-293 ◽  
Author(s):  
Gang Jin ◽  
Qichang Zhang ◽  
Shuying Hao ◽  
Qizhi Xie
Keyword(s):  
Helix Angle ◽  
Milling Process ◽  
Force Model ◽  
Stability Prediction ◽  
Chatter Vibration ◽  
Variable Pitch ◽  
Tool Geometries ◽  
Variable Helix ◽  
Piecewise Continuous ◽  
The Stability

The use of variable pitch or helix cutters is a known means to prevent chatter vibration during milling. In this article, an alternative method based on an improved semi-discretization method is proposed to predict the stability of variable pitch or variable helix milling. In order to consider the effect of distributed system delays attributed to helix variation, the average delays were calculated for each flute after the engaged cutting flutes were divided into a finite number of axial elements. Meanwhile, a straightforward integral force model, which can consider the piecewise continuous regions of the cutting that describe the helix angle is used to determine the cutting force. Through comparisons with prior works, time-domain simulations, and cutting tests, the proposed approach was verified. In addition, the method was applied to examine the effect of tool geometries on stability trends. Several phenomena for certain combinations of pitch and helix angles are shown and explained.

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