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One of the most important constraints on manufacturing productivity is the machining vibrations. This vibrations may cause increase in machining costs, lower accuracy of products and decrease tool life. The effective solution for increasing cutting process stability and vibration suppression is to improve structural dynamic stiffness. There has been presented different techniques for enhancing dynamic stiffness of structures using passive and active vibration control methods. Although passive vibration control methods are always stable, they exhibit limited performance. In active control methods, vibrations can be effectively damped over a various conditions. The aim of this research is to enhance the dynamic stiffness of an industrial boring bar by using active damping. Cutting process mainly exposed to parameter perturbations and unknown external disturbances, therefore, designing an active vibration control system for cutting process is a challenging problem. In this research an extended state observer based control strategy was proposed that can overcome these uncertainties. The proposed strategy was implemented into an active vibration control system for a boring bar. Moreover, the direct velocity feedback is successfully implemented in the vibration control loop. The results of impact tests indicate that the control algorithms have a great performance in suppressing vibrations and increasing the structural dynamic stiffness. Voltage impact results show that ADRC controller spends less control effort than direct velocity feedback controller.

Keywords: Boring bar, active damping, vibration control, ADRC method

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