Model hybrid magnetorheological damping prediction in machine tools

Vibration is an unbalance effect generated at the tool-workpiece interface during mechanical machining operations. Vibration is one of the most significant problems encountered when increasing material removal rate. It may contribute to tool wear and reduced surface finishing of the workpiece, which is referred to as ‘chatter’. However, to date, there are no significant experimental and corresponding simulation data for easy control with monitoring of the damping system model available to estimate parameters of machining F1140 Steel and to develop adequate models of magnetorheological damper (MRD) vibration control. This research adopts a novel approach to active dampers for MRD, which is manipulated by a control strategy to increase the dynamic structural damping characteristics of machine tools without changing actual machining operations. The operation of the system is actualized by the adoption of shock absorbers and active command of an MRD, thereby increasing the vibration-free zone with an electromagnetic actuator to reduce or possibly eliminate chatter during machining operations. A novel smart tool holder (STH) for real-time sensor data collection was designed in MATLAB, which for monitoring purposes is located at the tip of the tool during operation. The selection of data includes self-developed vibration, frequency monitoring, system stability evaluation, and the runout time. One of the objectives of the STH is to enable the accurate determination of a numerical control metal cutting system in vibration reduction. It was further designed to increase stability and the cutting force that can be achieved with the actuator and can facilitate the use of different control strategies or filters.