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High quality manufactured components with fast production rate is an increasing demand of modern machine tool industry. Internal machining operations due to the large length to diameter ratio are most prone to intolerable chatter vibrations and proved to be an extremely challenging process. This paper presents a new method for proper design of direct velocity feedback (DVF) controller in order to extend boundaries of stable cutting for internal turning with minimum control effort. Control effort and active damping performance are two counteracting parameters that affect the results of active vibration control. After properly implementing the DVF active control algorithm on the internal turning setup, stable boundaries for different control gains of DVF controller are thoroughly studied. The comparison shows that although high DVF gains may considerably improve dynamic stiffness of the tool, it leads to the maximum control effort and actuator saturation and consequently process instability. The proposed gain selection method results in a significant increase in stable machining over the desired range of cutting conditions. The suggested design approach of the DVF controller can considerably improve limitations of rough machining on long over hang boring bars.

High-performance controller design and evaluation for active vibration control in boring