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Hardware-in-the-loop Experiments on an Active Turning Tool with Robust LPV Control of Chatter Vibration

Authors:
Ziv Brand
Matthew O.T. Cole

Keywords: Active vibration control; Chatter suppression; Internal turning; Linear parameter varying control; H-infinity control

Abstract:
This study presents a control design for an active lathe cutting tool aimed at effectively suppressing vibration and chatter during internal turning operations. To address the variability in dynamic behavior caused by uncertainties in cutting parameters, a robust H_∞ controller was developed using a Linear-Parameter-Varying (LPV) model of the machining dynamics. This parametric approach allows real-time tuning of the control system properties in a workshop environment for optimal vibration reduction. The controller manages time-delayed feedback from cutting forces and mitigates spillover instability from unmodeled high-frequency modes. Integrated with piezoelectric actuators and sensors, the active tool holder maintains its original size and shape, ensuring ease of use in industrial applications. Experiments using a laboratory system that emulates chatter showed that the proposed system reduces root-mean-square vibration levels by over 65%, with peak-to-peak values reduced by approximately 47% in unstable cutting regimes. These results demonstrate the system’s feasibility for real-world machining environments, enabling higher material removal rates with improved surface finish.

Pages: 15 to 20

Copyright: Copyright (c) IARIA, 2025

Publication date: March 9, 2025

Published in: conference

ISSN: 2308-3913

ISBN: 978-1-68558-241-8

Location: Lisbon, Portugal

Dates: from March 9, 2025 to March 13, 2025