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Boring operations due to the large length to diameter ratio and the high flexibility of tool are prone to self-excited (chatter) vibration. This vibration may cause poor surface quality, low dimensional accuracy and tool breakage. In practice, chatter is the main limitation on production rate. The main reason of chatter phenomenon is the dynamic interaction between cutting process and structure of machine tool. By increasing the length of the cutting tool, the vibration tendency in the tool’s structure increases. Improving dynamic stiffness of the tool is the most effective solution for decreasing vibration and increasing chatter stability. For increasing the stability of the tool in long overhang boring operations, passive and active vibration control has been proposed and implemented. In active control methods, vibrations can be effectively damped over a various cutting conditions. The aim of this research is to enhance chatter stability of an industrial boring bar by increasing the dynamic stiffness. A VCA actuator is used for active vibration control. The designed setup can effectively suppress undesirable vibrations in the radial direction. First, modal parameters of the boring bar are determined by experimental modal analysis. Then, the transfer function of the actuator-tool setup is identified with the sweep frequency excitation. In the following, the direct velocity feedback is successfully implemented in the vibration control loop. The results of cutting tests indicate that the actuator has a great performance in suppressing vibrations and increasing the dynamic stiffness. Hence, the developed method can significantly increase chatter stability of boring operations.

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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.

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