Milling Chatter Control in Low Immersion Condition with an Active Electromagnetic Tool Holder System

Area of Science:

• Manufacturing Engineering
• Mechanical Vibrations
• Control Systems

Background:

• Chatter, a common issue in milling, degrades workpiece quality and reduces machining efficiency.
• Existing methods struggle with chatter control, especially in challenging conditions like low immersion milling.
• Thin-walled workpieces and tool flexibility exacerbate chatter problems.

Purpose of the Study:

• To propose and validate an active electromagnetic tool holder system for chatter suppression.
• To develop a time-delay output feedback control method tailored for low immersion milling.
• To address practical limitations such as actuator bandwidth and current constraints in the controller design.

Main Methods:

• Development of a noncontact two-degree-of-freedom active magnetic bearing (AMB) actuator.
• Integration of displacement sensors with the AMB actuator at the tool holder.
• Controller design considering thin-walled workpieces, tool flexibility, and physical actuator limitations.
• Numerical simulations and experimental validation under low immersion milling conditions.

Main Results:

• The active electromagnetic tool holder system demonstrated significant chatter reduction.
• Effective control of chatter was achieved for thin-walled workpieces.
• The system performed well under low immersion milling conditions, validating its practical applicability.

Conclusions:

• The proposed active electromagnetic tool holder system is effective in controlling chatter during milling.
• The developed control strategy successfully addresses chatter in thin-walled workpieces under low immersion conditions.
• This technology offers a promising solution for improving machining efficiency and surface finish.