Extended Model and Control of Regenerative Chatter Vibrations in Orthogonal Cutting

Turning machining is an important manufacturing process, widely used in industry. Dynamic interaction between the tool and the workpiece may cause regenerative chatter, which is associated with problems of poor surface finish, reduced product quality and low productivity. The demand for high accuracy motivates development of active vibration control methods that are based on realistic dynamical models of the turning process. This paper discusses the development of an active robust control law that is based on an extended regenerative chatter vibration model for orthogonal cutting. Its novelty stems from the way the workpiece elastic behavior is taken into consideration. The presented numerical results show that the vibration level can be reduced significantly, even in the presence of external disturbances, parametric uncertainty and (open loop) unstable machining conditions.