Active Control of Chatter in Milling Process Using Intelligent PD/PID Control

Abstract

Chatter is an obstacle for achieving high-quality machining process and high production rate in industries. Chatter is an unstable self-exciting phenomenon that leads to tool wear, poor surface finish, and downgrade the milling operations. A novel active control strategy to attenuate the chatter vibration is proposed. <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">PD/PID</i> controllers in combination with Type-2 Fuzzy logic were utilized as a control strategy. The main control actions were generated by <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">PD/PID</i> controllers, whereas the Type-2 Fuzzy logic system was used to compensate the involved nonlinearities. The Lyapunov stability analysis was utilized to validate the stability of Fuzzy <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">PD/PID</i> controllers. The theoretical concepts and results are proved using numerical simulations. Although <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">PD/PID</i> controllers have been used for chatter control in machining process, the importance of stability along with the implementation of Type-2 Fuzzy logic system for nonlinearity compensation was the main contribution. In addition, active control using an <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">Active Vibration Damper</i> placed in an effective position is entirely a new approach with promising practical results.