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Research Papers

Vibration Suppression in Cutting Tools Using a Collocated Piezoelectric Sensor/Actuator With an Adaptive Control Algorithm

[+] Author and Article Information
Peter P. Radecki, Kevin M. Farinholt, Matthew T. Bement

The Engineering Institute, Los Alamos National Laboratory, Los Alamos, NM 87545

Gyuhae Park1

The Engineering Institute, Los Alamos National Laboratory, Los Alamos, NM 87545gpark@lanl.gov

1

Corresponding author.

J. Vib. Acoust 132(5), 051002 (Aug 18, 2010) (8 pages) doi:10.1115/1.4001498 History: Received December 08, 2008; Revised February 16, 2010; Published August 18, 2010; Online August 18, 2010

The machining process is very important in many engineering applications. In high precision machining, surface finish is strongly correlated with vibrations and the dynamic interactions between the part and the cutting tool. Parameters affecting these vibrations and dynamic interactions, such as spindle speed, cut depth, feed rate, and the part’s material properties can vary in real time, resulting in unexpected or undesirable effects on the surface finish of the machining product. The focus of this research is the development of an improved machining process through the use of active vibration damping. The tool holder employs a high-bandwidth piezoelectric actuator with an adaptive positive position feedback control algorithm for vibration and chatter suppression. In addition, instead of using external sensors, the proposed approach investigates the use of a collocated piezoelectric sensor for measuring the dynamic responses from machining processes. The performance of this method is evaluated by comparing the surface finishes obtained with active vibration control versus baseline uncontrolled cuts. Considerable improvement in surface finish (up to 50%) was observed for applications in modern day machining.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

The active tool holder

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Figure 2

The ring-type piezoelectric stack actuator for used in the active tool holder

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Figure 3

Piezoelectric sensor versus laser vibrometer response at 500 Hz excitation

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Figure 4

Adaptive positive position feedback control

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Figure 5

A snap shot of test setup with a cantilever beam

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Figure 6

System response for Adaptive PPF control with added mass. (Top) Free vibration case. (Center) Static PPF control tuned to 6 Hz. (Bottom) Adaptive PPF control.

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Figure 7

Vibration reduction in the active tool holder under impact testing

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Figure 8

Tool vibration reduction in the first mode under random excitation

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Figure 9

Frequency response measured at the lathe

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Figure 10

Surface roughness performance (1200rpm, 127 μm/rev feed)

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Figure 11

Comparison of different surface quality

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