110. Design and development of two degree of freedom model with PID controller for turning operation

P. Suresh Prabhu1, R. Prathipa2, B. Shanmugasundaram3

1, 3Karpagam University, Coimbatore 21, India

2Sree Sakthi Engineering College, Coimbatore, India

3Corresponding author

E-mail: 1p_sureshprabhu@yahoo.co.in, 2chemsprathi@yahoo.co.in, 3bshan_india@rediffmail.com

Received 23 December 2015; received in revised form 25 February 2016; accepted 23 December 2016

DOI https://doi.org/10.21595/jme.2016.15762

Abstract. The objective is to develop a two degree of freedom model with PID controller for turning process to reduce regenerative chatter with the aim of improving productivity, quality of surface finish, tool life and reducing environmental noise caused by chatter. A system model consists of a workpiece subsystem and a cutting tool subsystem. The workpiece subsystem consists of mass, stiffness and damper. The cutting tool subsystem consists of mass, stiffness and damper. A Piezo actuator and sensor was embedded into the tool holder. A Mechatronic system has been proposed and developed for reducing tool vibration in lathe tool during machining. It consists of electrical and mechanical components; the controller is designed to control the chatter that occurs between the tool and the workpiece. The controller is used to send a feedback to the actuator. The controller is designed so that it suppresses the settling time and dampens the tool. The effective cutting stiffness and effective cutting damping are modeled as a spring and damper during machining. The original response of the system is modeled using transfer function method. Their output responses were obtained using Mat lab software.

Keywords: self-excited vibration, PID controller, dynamic cutting process, transfer function, step response.

References

[1]        Alwarsamy T., Balasubramanian R., Raja Kumar K., Sankarasubramanian B. Improvement of stability by optimal parameters using genetic algorithm. Advances in Vibration Engineering, Vol. 2, Issue 4, 2003, p. 388‑404.

[2]        Singh Harpreet, Singh S. P., Agarwal V. P. Active vibration control of a beam using virtual instrumentation software. International Conference on Smart Materials, Structures and Systems, India, 1999, p. 443‑448.

[3]        Yang John L., Chen Joseph C. A systematic approach for identifying optimum surface roughness performance in end-milling operations. Journal of Industrial Technology, Vol. 17, Issue 2, 2001.

[4]        Keraita J. N., Oyango H. J., Misoi G. K. Lathe stability charts via acoustic emission monitoring. African Journal of Science and Technology, Science and Engineering Series, Vol. 2, Issue 2, 2001, p. 81‑93.

[5]        Lipski J., Litak G., Rusinek R., Szabelski K., Teter A., Warminski J., Zaleski K. Surface quality of a work material influence on vibrations in a cutting process. Journal of Sound and Vibration, Vol. 252, Issue 4, 2002, p. 729‑737.

[6]        Huang Luke, Chen Joseph C. A multiple regression model to predict in-process surface roughness in turning operation via accelerometer. Journal of Industrial Technology, Vol. 17, Issue 2, 2001.

[7]        Karkosch H. J., Preumont A. Recent advances in active damping and vibration control. 8th International Conference on New Actuators, Germany, 2002, p. 248‑253.

[8]        Mauri E., Kato S., Hashimoto M. The mechanism of chatter vibration in a spindle-workpiece system: Part 1 Properties of self-excited chatter vibration in spindle-workpiece system. Journal of Engineering for Industry, Vol. 110, 1988, p. 236‑241.

[9]        Mauri E., Kato S., Hashimoto M. The mechanism of chatter vibration in a spindle-workpiece system: Part 2 Characteristics of dynamic cutting force and vibration energy. Journal of Engineering for Industry, Vol. 110, 1988, p. 242‑247.

[10]     Mauri E., Kato S., Hashimoto M. The mechanism of chatter vibration in a spindle-workpiece system: Part 3 Analytical considerations. Journal of Engineering for Industry, Vol. 110, 1988, p. 248‑253.

[11]     Lago T. L., Hakansson Lars Performance of a chatter control system for turning and boring applications. 4th GRACM Congress on Computational Mechanics, 2002.

[12]     Andren L., Hakansson L., Claesson I. Active Vibration Control of Boring Bar Vibrations. Blekinge Institute of Technology, Sweden, 2004, p. 139‑196.

[13]     Tobias S. A. Machine Tool Vibration. John Wiley, New York, 1965.

[14]     Willis M. J. Proportional-Integral-Derivative Control. University of Newcastle, 1999.

Cite this article

Suresh Prabhu P., Prathipa R., Shanmugasundaram B. Design and development of two degree of freedom model with PID controller for turning operation. Journal of Measurements in Engineering, Vol. 4, Issue 4, 2016, p. 224‑231.

 

Journal of Measurements in Engineering. December 2016, Volume 4, Issue 4

JVE International Ltd. ISSN Print 2335-2124, ISSN Online 2424-4635, Kaunas, Lithuania