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Semi-active control of tool vibration in hard turning using magnetorheological fluid damper

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Abstract

Chatter is a limiting factor that obstructs the process stability and surface finish in the machining of hard steels. Chatter control has been an active area of research for more than a century; new machine tools and cutting tools have been developed keeping chatter in mind; however, machining with existing conventional machine tools requires some adaptive techniques to combat chatter. In this article, a compact mono-tube magnetorheological damper is developed and implemented with real-time control to suppress chatter vibration. The experimental modal analysis of the cutting tool with the developed MR damper demonstrates improved damping and dynamic stiffness. A cutting tool model linked with the damper model is simulated in the Simulink workspace with ON/OFF control. The controller simulations demonstrate its timely activation of the control signal in response to vibration feedback. The experimental validation is carried out by machining AISI 01 and AISI D2 steel workpieces, commonly used in manufacturing dies and tools. Machining tests under various cutting conditions demonstrated that real-time control of the magnetorheological fluid damper could significantly improve surface finish and tool life compared to constant current.

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Data availability

All data generated or analysed during this study are included in this published article.

Abbreviations

DTM:

Dynamic testing machine

PID:

Proportional Integral Derivative

MR:

Magnetorheological

AISI:

American Iron and Steel Institution

TMD:

Tuned mass damper

CNC:

Computer Numerically Controlled

DC:

Direct current

F-D:

Force displacement

FFT:

Fast Fourier transform

k:

Is the stiffness coefficient

c:

Is the viscous damping coefficient

x:

Is the initial displacement of the piston

α:

Is the scaling factor

z:

Is the hysteretic variable

E:

Is Young’s modulus

Ixx :

Is area moment of inertia

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Acknowledgements

The authors would like to thank the support received from IMPacting Research INnovation and Technology (IMPRINT) Project No. IMPRINT/2016/7330 titled ‘Development of cost-effective magnetorheological (MR) fluid damper in two-wheeler and four-wheeler automobile to improve ride comfort and stability for rendering sensors and data acquisition system to experiment. The project was funded by the Ministry of Human Resource Development (MHRD) and the Ministry of Road Transport and Highways (MRTH), the Government of India.

Funding

Ministry of Education, India, IMPRINT/2016/7330, Hemantha kumar, Ministry of Road transport and Highways, IMPRINT/2016/7330, Hemantha kumar

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, 575025, India

    Suhas S. Aralikatti & Hemantha Kumar

Authors
  1. Suhas S. Aralikatti
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  2. Hemantha Kumar
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Correspondence to Hemantha Kumar.

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Aralikatti, S.S., Kumar, H. Semi-active control of tool vibration in hard turning using magnetorheological fluid damper. JMST Adv. (2024). https://doi.org/10.1007/s42791-024-00070-4

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  • DOI: https://doi.org/10.1007/s42791-024-00070-4

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