Design and development of two degree of freedom model with PID controller for turning operation

Abstract

The objective is to develop a two degree of freedom model with PID controller for turning process to reduce regenerative chatter with the aim of improving productivity, quality of surface finish, tool life and reducing environmental noise caused by chatter. A system model consists of a workpiece subsystem and a cutting tool subsystem. The workpiece subsystem consists of mass, stiffness and damper. The cutting tool subsystem consists of mass, stiffness and damper. A Piezo actuator and sensor was embedded into the tool holder. A Mechatronic system has been proposed and developed for reducing tool vibration in lathe tool during machining. It consists of electrical and mechanical components; the controller is designed to control the chatter that occurs between the tool and the workpiece. The controller is used to send a feedback to the actuator. The controller is designed so that it suppresses the settling time and dampens the tool. The effective cutting stiffness and effective cutting damping are modeled as a spring and damper during machining. The original response of the system is modeled using transfer function method. Their output responses were obtained using Mat lab software.