Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the controller effect for two distinct cases of one and three sinusoidal speed are presented and compared.

Volume Subject Area:
Manufacturing Systems
Topics:
Chatter, Turning, Wear, Control equipment, Degrees of freedom, Delay differential equations, Genetic algorithms, Machining, Stability, Surface quality
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Copyright © 2010
 by ASME
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