Optimization of Damped Dynamic Vibration Absorber To Control Chatter in Metal Cutting Process

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Optimization of damped dynamic vibration absorber to control chatter in


metal cutting process

Article  in  Journal of Vibration and Control · February 2013


DOI: 10.1177/1077546313492554

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Article
Journal of Vibration and Control
2015, Vol 21(5) 949–958

Optimization of damped dynamic ! The Author(s) 2013


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vibration absorber to control chatter DOI: 10.1177/1077546313492554
jvc.sagepub.com
in metal cutting process

Sundaram Saravanamurugan1,
Thirunarayanaswamy Alwarsamy2 and Kaliyannan Devarajan1

Abstract
This paper deals with finding the optimum parameters of a damped dynamic vibration absorber (DVA) to control chatter
in metal cutting systems. The performance of conventional damped DVA is compared with the proposed skyhook
damper in which the damper of the absorber system is connected between the absorber mass and an inertial reference
in the sky, referred to as a skyhook damper. The damped DVA is optimized by reducing the magnitude in the positive side
and increasing it in the negative side of the real part of the frequency response function of the main system. The optimum
frequency ratio and the damping ratio of the damped DVA for the undamped and damped main system are obtained using
analytical solutions and a numerical optimisation technique, viz genetic algorithm, respectively. The performance of the
proposed skyhook damper is marginally better than the conventional type of damped DVA in controlling the vibration
of the main system. This is verified by analyzing both the proposed and conventional models using finite element
method-based commercial software ANSYS.

Keywords
Chatter control, conventional damped DVA, skyhook damper, genetic algorithm, ANSYS

established that the dynamic vibration absorber can


1. Introduction reduce the magnitude of the frequency response func-
Chatter in machining processes is a relative vibration tion (FRF) of the cutting tool and the vibrations can be
between the cutting tool and the workpiece that causes suppressed effectively in the cutting process when the
several adverse effects such as poor surface finish, dynamic vibration absorber is attached to the cutting
dimensional inaccuracy, tool wear and unacceptable tool. A piezo inertia actuator was used for the suppres-
noise. Tobias (1965), Merritt (1965), and Altintas sion of chatter in turning operations. Moradi et al.
(2000) have done several studies on regenerative chatter (2008) found optimum specifications of a tunable vibra-
and prediction of stability limits of various machining tion absorber based on the mode summation method
processes. Various methods have been proposed over for chatter control in a boring manufacturing process.
the years for preventing chatter in the machining pro- Chung et al. (1997) proposed an active vibration con-
cess, using passive and active vibration control tech- trol damper to reduce the size of the negative real part
niques. Rivin and Kang (1992) proposed a method to of the structural modes in order to improve the stability
improve the dynamic stability of a boring bar using of a high speed machine tool. Pratt and Nayfeh (2001)
DVA. They found optimum tuning ratio of DVA by
applying Routh stability criterion for the characteristic 1
Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham
equation of a two-degree-of-freedom (DOF) lumped University, Coimbatore, India
parameter model of a boring bar with DVA. Tewani 2
Directorate of Technical Education, Chennai, Tamil Nadu, India
et al. (1995) described the use of an active dynamic Received: 28 September 2012; accepted: 28 April 2013
vibration absorber to control chatter in a boring bar.
Improvement of stability boundaries for a chatter-free Corresponding author:
Sundaram Saravanamurugan, Department of Mechanical Engineering,
cutting operation of a boring bar with a passive tuned Amrita Vishwa Vidyapeetham University, Amrita School of Engineering,
mass damper and a boring bar with active dynamic Amrita Nagar, Coimbatore, Tamil Nadu, India.
absorber were compared. Tarng et al. (2000) Email: s_saravana@cb.amrita.edu

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950 Journal of Vibration and Control 21(5)

demonstrated the simple feedback on the parameter generated in the previous pass. The width of cut at the
space of chatter-free machining in a boring process stability limit based on the regeneration in the machin-
using theory and experiment. They also showed that ing process can be expressed using the equation, as sug-
active control of tool damping in each of the principal gested by Altintas (2000) alim ¼ 1/2 KfG(o), where alim
modal directions led to quite effective chatter suppres- is the critical depth of cut, Kf is the cutting constant,
sion. Koo and Ahmadian (2002) investigated the G(o) is the real part of the transfer function of the
dynamic characteristics of semi-active ground hook metal cutting system and o is the chatter frequency.
tuned vibration absorbers and the results were com- According to the equation, it is understood that the
pared with those of passive tuned vibration absorbers. critical depth of cut alim is inversely proportional to
Mei (2005) designed an active feedback wave controller the magnitude of the real part of the FRF of the cutting
to absorb chatter vibration energy in a broad frequency tool. So it is necessary to minimize the magnitude of
band to improve machining performance of a boring FRF in order to obtain a larger critical depth of cut
process by considering a real distributed cutting system alim. As the real part of FRF affects the machining sta-
model. Ganguli et al. (2006) constructed a two-DOF bility, the tuning methodologies used to find the opti-
mechatronics simulator to propose active damping as mal parameters of damped dynamic vibration
a strategy for control of chatter during milling oper- absorbers are (i) equal peaks of real part tuning and
ations. They used the active vibration control to stabil- (ii) equal troughs of real part tuning.
ize all kinds of milling operations by raising the
stability limit. Ganguli et al. (2007) demonstrated the 3. Optimization of damped dynamic
effect of active damping on regenerative chatter
vibration absorbers
instability for a turning operation and it was proved
that active damping can successfully enhance the sta- In this study, the conventional damped DVA shown in
bility limits. Huyanan and Sims (2007) compared the Figure 1 is referred to as Model A and the proposed
performance of passive and active vibration absorber skyhook damper shown in Figure 2, as Model B. The
control using root locus technique and it was concluded locked points theory that Sims (2007) used to find the
that the virtual passive absorber control is easier to optimum tuning parameters for Model A is applied to
implement than the virtual skyhook damping for the find the optimum tuning parameters of Model B and
improvement of machining stability. Sims (2007) devel- the results are compared with that of Model A. The
oped a vibration absorber tuning solution to control equation of motion of Model B is given by
machine tool chatter. It was proved that the tuning      
methodology based on optimizing the real part of mt 0 x€ t ct 0 x_ t
þ
FRF considerably improves the machining stability. 0 ma x€ a 0 ca x_ a
Liu and Liu (2005) compared Den Hartog’s (1985)     
kt þ ka ka xt F
method of finding optimum tuning parameters of con- þ ¼ sinð!tÞ ð1Þ
ventional damped DVA and a skyhook damper with ka ka xa 0
that of Brock’s method. To find the optimum tuning
parameters of the skyhook damper, Liu and Coppola
(2010) used the equal peaks tuning method, which may
not be useful in metal cutting applications. The main
objective of this work is to find the optimum tuning
parameters of the skyhook damper by optimizing the
real part of the FRF of the main system and compare
its performance with that of conventional damped
DVA. In this paper, the optimum parameters of a sky-
hook damper are calculated analytically for the
undamped main system and a numerical optimization
technique is used for the damped main system.

2. Theory of regenerative chatter in


machining process
Regenerative chatter is considered to be one of the most
important causes of instability in the cutting process.
The regenerative effect is caused by the superposition of
successive cuts, where the tool removes a wavy surface Figure 1. Model A.

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Saravanamurugan et al. 951

Figure 2. Model B.
Figure 3. Real part of the frequency response function (FRF) of
Model B.
Table 1. Non-dimensional parameters.

Mass ratio  ¼ ma =mt As the focus is to find the optimum tuning parameters
Non-dimensional excitation frequency  ¼ !=!t for an undamped main structure, the value of t of
pffiffiffiffiffiffiffiffiffiffiffi
Main system natural frequency !t ¼ kt =mt equation (3) is assumed to be zero in this section.
Main system damping ratio t ¼ ct =2!t mt Then the magnification factor for a range of values of
pffiffiffiffiffiffiffiffiffiffiffiffi non-dimensional frequency  is calculated using three
Absorber natural frequency !a ¼ ka =ma
Absorber damping ratio a ¼ ca =2!a ma values of absorber damping: a ¼ 0, a ¼ 0.05 and
Frequency ratio  ¼ !a =!t a ¼ 1 for  ¼ 1 and  ¼ 0.01 and the results are
plotted in Figure 3.
It can be observed that there are three locked points
at which the response G() is not affected by damping
of the absorber. The response curves are passing
where mt, kt, and ct are the mass, stiffness, and damping through three locked points, as shown in Figure 3,
value of the primary system, respectively; ma, ka, and ca regardless of different values of absorber damping
are the mass, stiffness, and damping value of the absor- ratio. In order to find the locked frequencies, the
ber system, respectively; F and ! are the amplitude and expression for Re(G()) can be solved by using the con-
frequency of the exciting force, respectively; xt and xa dition a ¼ 0 and a ¼ 1. The locked frequencies cor-
are the displacement of the primary mass and the respond to the positive and negative responses of the
absorber mass, respectively. By introducing the non- real part of FRF, denoted as p and n respectively. The
dimensional terms in Table 1, the magnification factor expression of p and  n are obtained using the follow-
of the main system as a function of non-dimensional ing steps:
frequency is given as
Step 1: when a ¼ 0, equation (3) is reduced to
X1 ð2  2 þ i2a Þ
GðÞ ¼ ¼8 9 ð2Þ
st < ðð1  2 Þð2  2 Þ  2 2 = ð2  2 Þðð1  2 Þð2  2 Þ  2 2 Þ ¼ 0 ð4Þ
4t a 2 Þ þ i2ðt ð2  2 Þ
: ; The solution for equation (4) is obtained as
þða ð1  2 þ 2 ÞÞÞ
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
The real part of equation (2) is given by u
u
tð1 þ  þ  Þ þ ð1 þ 2 þ 2 Þ2  42
2 2
  p ¼ ð5Þ
ð2  2 Þðð1  2 Þð2  2 Þ  2 2 Þ 2
þ 4a2 2 2 ð1  2 þ 2 Þ vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ReðGðÞÞ ¼   u qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ððð1  2 Þð2  2 Þ  2 2 Þ  4t a 2 Þ2 u
tð1 þ  þ  Þ  ð1 þ 2 þ 2 Þ2  42
2 2
þ4ða ð1  2 þ 2 Þ þ t ð2  2 ÞÞ2 n ¼ ð6Þ
ð3Þ 2

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952 Journal of Vibration and Control 21(5)

Table 2. Optimum frequency ratio for undamped main system.

Tuning methods Model A Model B


1 1
Equal peaks opt ¼ opt ¼ pffiffiffiffiffiffiffiffiffiffiffiffi
1þ 1þ
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi pffiffiffipffiffiffiffi
 þ 2 þ 2 þ 2 2  2 þ 2 
Equal troughs of real part 2opt,n ¼ 2opt,n ¼
2ð1 þ Þ2 2  5 þ 22
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi pffiffiffipffiffiffiffi
 þ 2  2 þ 2 2  2  2 
Equal peaks of real part 2opt,p ¼ 2opt,p ¼
2ð1 þ Þ2 2  5 þ 22

Figure 4. Optimum tuning ratio when t ¼ 0.

Step 2: Similarly, when a ¼ 1, equation (3) is pffiffiffipffiffiffiffi


reduced to 2  2  2 
2opt,p ¼ ð10Þ
2  5 þ 22
42 2 ð1  2 þ 2 Þ ¼ 0 ð7Þ
To find the optimum damping ratio, the locked points
The solution for equation (7) is obtained as, are made the maximum points in the frequency curve.
This requires zero slopes at the locked points.
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
a ¼ 1 þ 2 ð8Þ According to Den Hartog (1985), this can be done by
differentiating G() with respect to  and equating it to
The necessary condition for better machining stability zero. The differentiation process is done using Maple
is that the response of the main system at a is equal to software and the result for the optimum damping ratio
the response at either p or at n. To apply this condi- at locked frequencies is given as follows:
tion, the non-dimensional response G() at  ¼ a is pffiffiffipffiffiffiffi pffiffiffi
equated to G() at  ¼ p or  ¼ n and is solved to 2 3 ð3  2 2   22  2 þ 23=2 2Þ
find the optimum frequency ratio, by using a symbolic opt,n ¼ p ffiffi
ffi p ffiffi
ffi p ffiffi
ffipffiffiffiffi
4 25=2 2  82 þ 3=2 2 þ 10  2 2   4
algebra computer software Maple. The optimum fre-
quency ratios are obtained as follows: ð11Þ
pffiffiffipffiffiffiffi pffiffiffi
pffiffiffipffiffiffiffi 3 ð3  2 2  þ 22 þ 2  23=2 2Þ
2  2 þ 2  2
opt,p ¼ pffiffiffi pffiffiffi pffiffiffipffiffiffiffi
2opt,n ¼ ð9Þ 4 25=2 2 þ 82 þ 3=2 2  10  2 2  þ 4
2  5 þ 22
ð12Þ

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Saravanamurugan et al. 953

Figure 5. Optimum damping ratio when t ¼ 0.

To compare the analytical solutions for optimum


tuning ratio of Model B with Model A, the results are
tabulated as shown in Table 2. The variation of opti-
mum tuning parameters of Model A that was found by
Sims (2007) and the proposed Model B for a range of
values of mass ratio m for an undamped system are
shown in Figures 4 and 5. The results show that the
optimum tuning ratios and damping ratios of Model B
are greater than those of Model A. It is shown in sub-
sequent sections that the proposed Model B is more
effective than Model A in controlling the vibration
response of the main system and this result is also sub-
stantiated by doing finite element (FE) vibration ana-
lysis using FE commercial code ANSYS.

4. Numerical optimization using


genetic algorithm Figure 6. Numerical optimization result: optimum tuning ratio
of Model A and B for damped main system. (Equal troughs of real
Although the optimum tuning parameters of Model B part tuning).
for the undamped main system are found using locked
point theory, the same theory cannot be extended to the
damped main system; hence a numerical optimization techniques in a probabilistic manner. The optimization
technique is used. To obtain the optimum frequency is carried out by means of a GA implemented in
ratio and optimum damping ratio of Model B for the MATLAB. The real part of FRF, equation (3), is the
damped main system, a numerical optimization tech- objective function, which is to be optimized to find the
nique, namely a genetic algorithm (GA) is employed. optimum tuning parameters of Model B. The optimiza-
Genetic algorithm is an optimization algorithm based tion of the two design variables, namely frequency ratio
on the mechanics of natural genetics and natural selec- and damping ratio, is done by maximizing the negative
tion. GA operates on a population of potential solu- real part of FRF which has proved to be critical (Sims,
tions by applying the principle of the ‘‘survival of the 2007) in improving the machining stability. The results
fittest’’ to produce successively better approximations of numerical optimization for a range of values of mass
to a solution. GA is a kind of adaptive stochastic search ratio for various main system damping ratios are shown
and optimization algorithm based on fundamental evo- in Figure 6. The results show that optimum tuning
lutionary processes such as selection, crossover and ratios of Model B are greater than those of Model A,
mutation. This algorithm simulates the natural selec- which is similar to the results obtained for an
tion, crossover and mutation through numerical undamped main system. To compare the effectiveness

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954 Journal of Vibration and Control 21(5)

Figure 7. Non-dimensional response of undamped main system. (Equal troughs of real part tuning).

Figure 8. Non-dimensional response of damped main system for mass ratio 0.01. (Equal troughs of real part tuning).

of the various optimum tuning methodologies, the 5. Finite element vibration analysis
response of the main system G() is plotted for various
of boring bar with absorber
values of non-dimensional frequency . The results for
the mass ratio  ¼ 0.01 and  ¼ 0.05 are shown in An equivalent lumped mass model of a boring bar is
Figure 7, for the undamped main system. The non- considered as the main system to predict the vibration
dimensional response of the main system is reduced control capabilities of both conventional damped DVA
by 2% for lower mass ratio and by 5% for higher and a skyhook damper. First, the bending mode of the
mass ratio, when the skyhook damper (Model B) is boring bar is selected as the target mode to be damped.
used. The results show that the skyhook damper is The frequency of the first bending mode is discovered
more effective than conventional damped DVA in using the bandwidth method. The experimental setup,
improving machining stability. Similar results can also used to measure the natural frequency of the boring bar
be seen in the case of the damped main system that is shown in Figure 9, consists of an accelerometer, Photon
shown in Figure 8. data acquisition system and a Dytran impulse hammer.

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Saravanamurugan et al. 955

The boring bar was excited using the impulse given in Table 3. A finite element model of the two-
hammer, and the resultant amplitude was measured DOF system shown in Figure 11, is created using
using the accelerometer. The data acquisition system COMBIN–14, a spring damper element and a MASS-
gathered the data and RT Pro software was used to 21 element. The COMBIN-14 is a two-noded longitu-
calculate the FRF, which is shown in Figure 10. dinal spring damper element. It has three DOF at each
Having found the natural frequency of the boring node: translation in the nodal x, y, and z coordinate
bar, the harmonic analysis of a two-DOF model of a directions. This element can be used to model both the
boring bar with damped dynamic vibration absorbers conventional damped DVA and the skyhook damper as
(Model A and B) is done using ANSYS. Harmonic it is possible to remove the spring or damping capabil-
analysis is used to find the FRF of a vibrating ities from it. MASS-21 is a single-noded lumped mass
system, which is required to assess the performance of element with six DOF: translations in the nodal x, y,
the proposed skyhook damper. Various parameters of and z coordinate directions and rotations about the
the boring bar and the two types of damped dynamic nodal x, y, and z axes. To analyze the vibration
vibration absorbers, used in the harmonic analysis, are response of the two-DOF model of the boring bar
and damped DVA, only the translation in the nodal y
coordinate direction of both the elements is used.
As harmonic analysis requires a range of forcing
frequencies that depend on the resulting two new nat-
ural frequencies with attachment of damped DVA to
the boring bar, modal analysis is done to find these two
new natural frequencies. From the results of the modal
analysis shown in Table 4, the forcing frequency range
is chosen to be from 400 to 750 Hz, within which the
harmonic load is applied on the system. The real part of
the FRF of the main system, which gives the values of
amplitude at various forcing frequencies, is found using
harmonic analysis.
The results of harmonic analysis are shown in
Figure 9. Experimental setup. Figures 12 and 13, for two different mass ratios, viz

Figure 10. Frequency response function of boring tool.

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956 Journal of Vibration and Control 21(5)

Table 3. Parameters of boring bar and vibration absorber.

Boring bar specifications (main system) Conventional damped DVA (Model A) Skyhook damper (Model B)

Length (L) ¼ 0.18 m Maximization of negative Maximization of negative


Area of cross section (A) ¼ 4.84  104 m2 real part of FRF real part of FRF
Area moment of inertia (I) ¼ 19.5  109 m4  aopt fopt  aopt fopt
Density (r) ¼ 7850 Kg/m3 0.01 1.026 0.062 0.01 1.043 0.063
Young’s modulus (E) ¼ 200 GPa
0.05 1.037 0.137 0.05 1.123 0.149

Minimization of positive Minimization of positive


real part of FRF real part of FRF
 aopt fopt  aopt fopt
0.01 0.957 0.061 0.01 0.969 0.059
0.05 0.886 0.130 0.05 0.948 0.083
DVA: dynamic vibration absorber; FRF: frequency response function.

 ¼ 0.01 and 0.05, for both skyhooks damper and conventional damped DVA.

Table 4. Modal analysis results.

Description of model Frequency ratio () Mass ratio () Natural frequency (Hz)

Boring bar with conventional 0.01 1.026 540, 599


damped DVA (Model A) 0.05 1.037 510, 642
0.01 0.957 521, 580
0.05 0.886 468, 597
Boring bar with skyhook 0.01 1.043 543, 606
damper (Model B) 0.05 1.123 522, 679
0.01 0.969 525, 582
0.05 0.948 489, 612
DVA: dynamic vibration absorber.

Figure 11. Finite element model of vibrating system.

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Saravanamurugan et al. 957

Figure 12. Response of the main system for mass ratio  ¼ 0.01.

Figure 13. Response of the main system for mass ratio  ¼ 0.05.

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958 Journal of Vibration and Control 21(5)

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