Semi-active fuzzy control of machine tool chatter vibration using smart MR dampers

Dynamic stability of cutting processes against chatter vibration is a key requirement for high-speed machining and high material removal rate with high-quality surface finish. In the present work, the stiffness and damping of the machine tool are varied semi-actively by means of a magnetorheological (MR) damper to suppress chatter. An integrated mechatronic model is presented for the chatter analysis of a machine tool equipped with MR damper. Since the structure becomes nonlinear in the presence of MR damper, a novel chatter detection index (CDI) is developed to detect chatter from time-domain vibration signals. Subsequently, a fuzzy controller is designed to compute the best supply voltage to MR damper based on the measured vibration signals. The obtained results from the numerical analysis of the integrated model are encouraging, demonstrating a significant improvement in the dynamic stability of machining process, as well as the ability of detecting and suppressing chatter.