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Optimization of Damped Dynamic Vibration Absorber To Control Chatter in Metal Cutting Process
Optimization of Damped Dynamic Vibration Absorber To Control Chatter in Metal Cutting Process
Optimization of Damped Dynamic Vibration Absorber To Control Chatter in Metal Cutting Process
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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
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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.
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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)
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Saravanamurugan et al. 953
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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
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956 Journal of Vibration and Control 21(5)
Boring bar specifications (main system) Conventional damped DVA (Model A) Skyhook damper (Model B)
¼ 0.01 and 0.05, for both skyhooks damper and conventional damped DVA.
Description of model Frequency ratio () Mass ratio () Natural frequency (Hz)
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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)
The results indicate that amplitude of the main Ganguli A, Deraemaeker A, Romanescu I, Horodinca M and
system is reduced by 2% for lower mass ratio Preumont A (2006) Simulation and active control of chat-
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