Adaptive Active Chatter Control in Milling Processes

Abstract

Chatter is an undesirable dynamic phenomenon in machining processes, which causes cutting disturbance, overcut, quick tool wear, etc., and thus seriously impairs workpiece quality. To mitigate chatter, traditional methods called passive control focus on optimizing working spindle speeds and depths of cut. But they have inherent disadvantages in gaining highly efficient machining. On the contrary, the research in this paper is along the line of active control. Specifically, an adaptive algorithm is developed based on Fourier series analysis to deal with the socalled regenerative cutting force which causes chatter. As a result, chatter is remarkably mitigated. The performance improvement is illustrated by numerical simulation in terms of both stability lobes diagram (SLD) and surface location error (SLE).