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Research Papers

Active Delayed Control of Turning and Milling Dynamics

[+] Author and Article Information
Xinhua Long

Mem. ASME
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: xhlong@sjtu.edu.cn

Pingxu Zheng

State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhenghenrry@hotmail.com

Song Ren

State Key Laboratory of Mechanical
System and Vibration,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: mapping@sjtu.edu.cn

1Corresponding author.

Contributed by the Design Engineering Division of ASME for publication in the JOURNAL OF COMPUTATIONAL AND NONLINEAR DYNAMICS. Manuscript received June 9, 2016; final manuscript received May 18, 2017; published online June 16, 2017. Assoc. Editor: Dumitru Baleanu.

J. Comput. Nonlinear Dynam 12(5), 051022 (Jun 16, 2017) (10 pages) Paper No: CND-16-1266; doi: 10.1115/1.4036913 History: Received June 09, 2016; Revised May 18, 2017

In this paper, a novel controller is developed for control of turning and milling dynamics. The controller design benefits from the use of time-delays in controlling a dynamic system. The gains of the controller are determined by using the discrete optimal control method. Numerical simulations are carried out in order to verify the efficiency of the controller. The findings show that the designed controller can be effective in suppressing chatter in both turning and milling processes as well as improve the stability of the cutting processes with the introduced time-delay. The authors discuss the influence of designed time-delay on control performance and robustness, and point out the advantages of using a time-delayed controller for controlling cutting dynamics.

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Figures

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Fig. 1

Stable and unstable cutting at 1680 r/min without and with control: (a) chip width b = 0.7 mm and (b) chip width b = 0.9 mm

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Fig. 2

Limiting chip width variation with time-delay

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Fig. 3

Stability diagram of turning operation: (a) τ′<6.2 ms and (b) τ′>6.2 ms

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Fig. 4

Robustness of time-delay: (a) τ′=10 ms and (b) τ′=13 ms

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Fig. 5

Control force variation with time-delay

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Fig. 6

Workpiece-tool system model

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Fig. 7

Active control of stable milling at 5500 r/min: (a1) and (b1) Cutter displacement in time domain simulation, (a2) and (b2) zoom in diagrams of (a1) and (b1), and (a3) and (b3) amplitude spectrum of cutter displacement

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Fig. 8

Active control of unstable milling at 5500 r/min: (a1) and (b1) cutter displacement in time domain simulation and (a2) and (b2) amplitude spectrum of cutter displacement

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Fig. 9

Stability chart with given time-delay controller in the x- and y-directions

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Fig. 10

Bifurcation diagram for spindle speed at 3750 r/min: (a) without control and (b) with control

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Fig. 11

Bifurcation diagram for spindle speed at 7500 r/min: (a) without control and (b) with control

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Fig. 12

Stability chart with given time-delay for 25% immersion ratio

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