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Active Vibration Control of Boring Bar Vibrations

  • Andrén, Linus
  • Håkansson, Lars
Publication Date
Jan 01, 2004
DiVA - Academic Archive On-line
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The boring operation is a cumbersome manufacturing process plagued by noise and vibration-related problems. A deep internal boring operation in a workpiece is a classic example of chatter-prone machining. The manufacturing industry today is facing tougher tolerances of product surfaces and a desire to process hard-to-cut materials; vibrations must thus be kept to a minimum. An increase in productivity is also interesting from a manufacturing point of view. Penetrating deep and narrow cavities require that the dimensions of the boring bar are long and slender. As a result, the boring bar is inclined to vibrate due to the limited dynamic stiffness. Vibration affects the surface finish, leads to severe noise in the workshop and may also reduce tool life. This report presents an active control solution based on a standard boring bar with an embedded piezo ceramic actuator; this is placed in the area of the peak modal strain energy of the boring bar bending mode to be controlled. An accelerometer is also included in the design; this is mounted as close as possible to the cutting tool. Embedding the electronic parts not only protects them from the harsh environment in a lathe but also enable the design to be used on a general lathe as long as the mounting arrangements are relatively similar. Three different algorithms have been tested in the control system. Since the excitation source of the original vibrations, i.e. the chip formation process cannot be observed directly, the algorithms must be constructed on the basis of a feedback approach. Experimental results from boring operations show that the vibration level can be reduced by 40 dB at the resonance frequency of a fundamental boring bar bending mode; several of its harmonics can also be reduced significantly.

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