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Active chatter control in turning processes with input constraint

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Abstract

Regenerative chatter is an annoying dynamic phenomenon in machining processes. In this paper, an adaptive sliding mode controller (SMC) is developed for turning chatter mitigation in the presence of control input constraint, parameter uncertainties, and external disturbances. Adaptive laws are employed to estimate parameter uncertainties and disturbances, while a SMC, fulfilling the control input constraint, is designed to mitigate chatter. One unique feature of the developed adaptive approach is that it guarantees chatter suppression even in the presence of control input constraint. Theoretical analyses and experimental investigations are performed, and results demonstrate that the developed SMC with chosen controller parameters guarantees chatter mitigation in the tested examples.

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Abbreviations

K f :

Cutting coefficient

F f :

Dynamic cutting force

x(t):

Vibration displacement

m, c, k :

Mass, damping, and stiffness, respectively.

w :

Width of cut

u(t):

Control input

u m :

Threshold of control input

d(t):

Generalized uncertainty

sat():

Saturation function

n :

Spindle speed

k 1 :

Upper bound of total disturbance

ki (i = 2, 3, 4):

Positive scalars

s(t):

Sliding function

s0, c1, p, p1 :

Controller parameters

τ :

Time delay

τ0 :

Controller parameter

ψ :

System state vector

χ():

Coefficient function

λ :

Sliding function parameter

ε :

Boundary layer thickness

β:

Lower bound of output capacity

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Haifeng Ma

  2. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Haifeng Ma, Jianhua Wu & Zhenhua Xiong

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  1. Haifeng Ma
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  2. Jianhua Wu
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  3. Zhenhua Xiong
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Correspondence to Zhenhua Xiong.

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Ma, H., Wu, J. & Xiong, Z. Active chatter control in turning processes with input constraint. Int J Adv Manuf Technol 108, 3737–3751 (2020). https://doi.org/10.1007/s00170-020-05475-8

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