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In workshops where metal cutting is performed, the machining processes frequently introduces productivity degrading vibration problems and annoying sound, sometimes almost at unbearable levels. Besides producing disturbing noise, the vibrations affect the surface finish of the workpiece and the tool life. Two different approaches based on feedback control are investigated, both applied for the control of an active boring bar. The first approach is based on a digital adaptive feedback controller; the feedback filtered-X LMS algorithm. The second approach is based on an analog controller; a feedback controller with gain and phase orthogonally adjustable, thus flexible for the control of systems with different dynamic properties. Based on open loop frequency response function estimates, robustness and stability of both the digital and the analog feedback control system are discussed.

Chatter vibrations are causing large monetary losses daily in industry. New materials have increased the challenges with harmful vibration levels. Since the vibrations, when observed as a final result, are chaotic and the vibration process nonlinear, it is a challenging task to deal with it. It is also a common “understanding” in the cutting industry that chatter is RPM (the rotational speed) dependent, since the behavior changes with RPM. Many attempts have been done over many years to mitigate and understand the vibrations. In our vast research on these topics, we have found that it is rewarding to classify the vibrations into categories, enabling a better understanding of its underlying physics and “source of vibrations,” and thus also the formulation of a possible remedy. An analysis approach has been developed where vibrations are analyzed and categorized and a GO/NOGO indicator is telling if the machine has the “right type of vibrations.”