Advertisement

Vibration suppression of thin-walled workpiece milling using a time-space varying PD control method via piezoelectric actuator

  • Shuyu Wang
  • Qinghua SongEmail author
  • Zhanqiang Liu
ORIGINAL ARTICLE
  • 5 Downloads

Abstract

The vibration suppression and workpiece surface improvement of thin-walled workpiece milling are highly concerned due to the weak stiffness of the workpiece and the time variant of dynamic characteristics during milling process. In this paper, an active vibration control system is developed to suppress the vibration of thin-walled workpiece milling. The dynamic model of plate-actuator milling system is derived using Hamilton’s principle and solved using FEM method. Acceleration sensor and piezoelectric patch are selected as the sensor and actuator in the control system. Considering the time variant of dynamic characteristics and the position limit of sensor and actuator during milling process, a time-space varying PD (VPD) control method is presented and utilized. The VPD control method applies time varying control parameters. Some simulation and experimental validations are carried out to validate the effectiveness of the control system. The overall results indicate that the proposed control system perform well in suppressing the vibration of thin-walled workpiece milling process.

Keywords

Vibration control Thin-walled workpiece milling Piezoelectric actuator PD control 

Notes

Funding information

The authors are grateful to the financial supports of the National Natural Science Foundation of China (no. 51575319), the Major projects of National Science and Technology (Grant No. 2019ZX04001031), Natural Science Outstanding Youth Fund of Shandong Province (Grant No. ZR2019JQ19), and the Key Research and Development Plan of Shandong Province (no. 2018GGX103007). The authors declare that there is no conflict of interest.

Compliance with ethical standards

Conflict of interest

The authors declare that they have no conflict of interest.

References

  1. 1.
    Altintas Y, Budak E (1995) Analytical prediction of stability lobes in milling. Ann CIRP 44:357–362CrossRefGoogle Scholar
  2. 2.
    Budak E, Altintas Y (1998) Analytical prediction of chatter stability in milling – part I: general formulation. J Dyn Syst Meas Control 120(1):22–30CrossRefGoogle Scholar
  3. 3.
    Zhou X, Zhang DH, Luo M, Wu BH (2018) Chatter stability prediction in four-axis milling of aero-engine casings with bull-nose end mill. Chin J Aeronaut 28(6):1766–1773CrossRefGoogle Scholar
  4. 4.
    Long X, Jiang H, Meng G (2013) Active vibration control for peripheral milling processes. J Mater Process Technol 213(5):660–670CrossRefGoogle Scholar
  5. 5.
    Liu KJ, Rouch KE (1991) Optimal passive vibration control of cutting process stability in milling. J Mater Process Technol 28:285–294CrossRefGoogle Scholar
  6. 6.
    Sathianarayanan D, Karunamoorthy L, Srinivasan J, Kandasami K, Palanikumar K (2008) Chatter suppression in boring operation using magnetorheological fluid damper. Mater Manuf Process 23(4):329–335CrossRefGoogle Scholar
  7. 7.
    Mei DQ, Kong TR, Shih AJ, Chen ZC (2019) Magnetorheological fluid controlled boring bar for chatter suppression. J Mater Process Technol 209(4):1861–1870CrossRefGoogle Scholar
  8. 8.
    Mei DQ, Yao ZH, Kong TR, Chen ZC (2010) Parameter optimization of time-varying stiffness method for chatter suppression based on magnetorheological fluid-controlled boring bar. Int J Adv Manuf Technol 46(9–12):1071–1083CrossRefGoogle Scholar
  9. 9.
    Min W, Ting-Qi G, Jia F, Wei-Hong Z (2019) On improving chatter stability of thin-wall milling by prestressing. J Mater Process Technol 264:32–44CrossRefGoogle Scholar
  10. 10.
    Shamoto E, Mori T, Nishimura K, Hiramatsu T, Kurata Y (2010) Suppression of regenerative chatter vibration in simultaneous double-sided milling of flexible plates by speed difference. CIRP Ann Manuf Technol 59(1):387–390CrossRefGoogle Scholar
  11. 11.
    Kiran K, Dragos A, Adib B (2013) A solution for minimising vibrations in milling of thin walled casings by applying dampers to workpiece surface. CIRP Ann Manuf Technol 62(1):415–418CrossRefGoogle Scholar
  12. 12.
    Wan M, Dang XB, Zhang WH (2018) Optimization and improvement of stable processing condition by attaching additional masses for milling of thin-walled workpiece. Mech Syst Signal Process 103:196–215CrossRefGoogle Scholar
  13. 13.
    Yuan H, Wan M, Yang Y (2019) Design of a tunable mass damper for mitigating vibrations in milling of cylindrical parts. Chin J Aeronaut 32:748–758CrossRefGoogle Scholar
  14. 14.
    Wang C, Zhang X, Liu Y, Cao H, Chen X (2018) Stiffness variation method for milling chatter suppression via piezoelectric stack actuators. Int J Mach Tools Manuf 124:53–66CrossRefGoogle Scholar
  15. 15.
    Sajedi Pour D, Behbahani S (2016) Semi-active fuzzy control of machine tool chatter vibration using smart MR dampers. Int J Adv Manuf Technol 83(1-4):421–428CrossRefGoogle Scholar
  16. 16.
    Tewani SG, Rouch KE, Walcott BL (1995) A study of cutting process stability of a boring bar with active dynamic absorber. Int J Mach Tool Manu 35(1):91–108CrossRefGoogle Scholar
  17. 17.
    Zhang YM, Sims ND (2005) Milling workpiece chatter avoidance using piezoelectric active damping: a feasibility study. Smart Mater Struct 14:65–70CrossRefGoogle Scholar
  18. 18.
    Venter GS, Silva LMDP, Carneiro MB, Maira MDS (2017) Passive and active strategies using embedded piezoelectric layers to improve the stability limit in turning/boring operations. Int J Adv Manuf Technol 89(9-12):2789–2801CrossRefGoogle Scholar
  19. 19.
    El-Sinawi AH, Kashani R (2005) Improving surface roughness in turning using optimal control of tool’s radial position. J Mater Process Technol 167:54–61CrossRefGoogle Scholar
  20. 20.
    Brecher C, Manoharan D, Ladra U, Kopken H-G (2010) Chatter suppression with an active workpiece holder. Prod Eng 4:239–245CrossRefGoogle Scholar
  21. 21.
    da Silva MM, Cervelin JE, Calero DP, Coelho RT (2013) Availability study on regenerative chatter avoidance in turning operations through passive and active damping. Int J Mechatron Manuf Syst 6(5/6):455–473Google Scholar
  22. 22.
    Tanaka H, Obata F, Matsubara T, Mizumoto H (1994) Active chatter suppression of slender boring bar using piezoelectric actuators. JSME Int J Ser C 37(3):601–606Google Scholar
  23. 23.
    Crawley EF, de Luis J (1987) Use of piezoelectric actuators as elements of intelligent structures. AIAA J 25(10):1373–1385CrossRefGoogle Scholar
  24. 24.
    Rofooei FR, Nikkhoo A (2009) Application of active piezoelectric patches in controlling the dynamic response of a thin rectangular plate under a moving mass. Int J Solids Struct 46(11-12):2429–2443CrossRefGoogle Scholar
  25. 25.
    Qiu ZC, Han JD, Zhang XM, Wang YC, Wu ZW (2009) Active vibration control of a flexible beam using a non-collocated acceleration sensor and piezoelectric patch actuator. J Sound Vib 326(3-5):438–455CrossRefGoogle Scholar
  26. 26.
    Song QH, Ai X, Tang WX (2011) Prediction of simultaneous dynamic stability limit of time-variable parameters system in thin-walled workpiece high-speed milling processes. Int J Adv Manuf Technol 55:883–889CrossRefGoogle Scholar
  27. 27.
    Song Q, Shi J, Liu Z, Yi W (2016) A time-space discretization method in milling stability prediction of thin-walled component. Int J Adv Manuf Technol 89:1–15CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical EngineeringShandong UniversityJinanPeople’s Republic of China
  2. 2.National Demonstration Center for Experimental Mechanical Engineering EducationShandong UniversityJinanPeople’s Republic of China

Personalised recommendations