Active chatter suppression by means of computer-controlled inertial actuators

Résumé

The productivity of metal cutting processes is limited by well known chatter vibrations. Chatter is a self-excited vibration created by the regenerative effect. Current machine tools are complex mechatronic structures full of sensors and drives where control laws are implemented. However, in these systems the measurement and action points are usually far from the cutting zone and, frequently, the actuation bandwidth is not wide enough to avoid self-excited vibrations and assure a proper dynamic behaviour. This PhD proposal will overcome these limitations, introducing inertial actuators and sensors as close as possible to the machining point.First of all, a Hardware in the Loop (HIL) demonstrator, where chatter process is reproduced, will be built. Here, different control strategies will be studied applying, by means of a small inertial actuator. The main purpose is to select the most suitable control law in controlled conditions. Later on, a mechatronic model will be implemented in Matlab framework, combining the milling simulation algorithms and different control laws. One of the objectives is to define design rules for dimensioning inertial actuators. Finally, the different laws will be tested in real cutting conditions, introducing a new inertial actuator in an industrial milling machine.