A Novel Hybrid Error Criterion-Based Active Control Method for on-Line Milling Vibration Suppression with Piezoelectric Actuators and Sensors

Xingwu Zhang; Chenxi Wang; Robert X Gao; Ruqiang Yan; Xuefeng Chen; Shibin Wang

doi:10.3390/s16010068

A Novel Hybrid Error Criterion-Based Active Control Method for on-Line Milling Vibration Suppression with Piezoelectric Actuators and Sensors

Sensors (Basel). 2016 Jan 6;16(1):68. doi: 10.3390/s16010068.

Authors

Xingwu Zhang^{1

2}, Chenxi Wang³, Robert X Gao⁴, Ruqiang Yan^{5

6}, Xuefeng Chen⁷, Shibin Wang⁸

Affiliations

¹ State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China. xwzhang@mail.xjtu.edu.cn.
² Department of Mechanical and Aerospace Engineering, Case Western Reserve University, Cleveland, OH 44106, USA. xwzhang@mail.xjtu.edu.cn.
³ State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China. wangchenxi@stu.xjtu.edu.cn.
⁴ Department of Mechanical and Aerospace Engineering, Case Western Reserve University, Cleveland, OH 44106, USA. robert.gao@case.edu.
⁵ Department of Mechanical and Aerospace Engineering, Case Western Reserve University, Cleveland, OH 44106, USA. ruqiang@seu.edu.cn.
⁶ School of Instrument Science and Engineering, Southeast University, Nanjing 210096, China. ruqiang@seu.edu.cn.
⁷ State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China. chenxf@mail.xjtu.edu.cn.
⁸ State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China. wangshibin2008@mail.xjtu.edu.cn.

Abstract

Milling vibration is one of the most serious factors affecting machining quality and precision. In this paper a novel hybrid error criterion-based frequency-domain LMS active control method is constructed and used for vibration suppression of milling processes by piezoelectric actuators and sensors, in which only one Fast Fourier Transform (FFT) is used and no Inverse Fast Fourier Transform (IFFT) is involved. The correction formulas are derived by a steepest descent procedure and the control parameters are analyzed and optimized. Then, a novel hybrid error criterion is constructed to improve the adaptability, reliability and anti-interference ability of the constructed control algorithm. Finally, based on piezoelectric actuators and acceleration sensors, a simulation of a spindle and a milling process experiment are presented to verify the proposed method. Besides, a protection program is added in the control flow to enhance the reliability of the control method in applications. The simulation and experiment results indicate that the proposed method is an effective and reliable way for on-line vibration suppression, and the machining quality can be obviously improved.

Keywords: active control; hybrid error criterion; milling process; vibration suppression.