Vibration surveillance supported by Hardware-In-the-Loop Simulation in milling flexible workpieces

• Description of the milling process and non-stationary system in hybrid coordinates.
• Control law derived on a basis of the process dynamics and energy performance index.
• Active force generation by the piezoceramic plate actuator applied.
• Hardware-In-the-Loop Simulations and real cutting experiment results included.
• Significant vibration reduction obtained.

The paper concerns modern approaches towards minimising the vibration level during the high speed milling process of flat flexible details. Dynamic analysis of the milling process is performed and dynamics of non-stationary controlled system in hybrid coordinates is described. On the basis of the process dynamics, as well as on the energy performance index, suitable control law is derived in order to reduce vibration level. This control law is applied for active force generation by the piezoceramic plate actuator. The implementation issues, which concern a proposed method of vibration surveillance, are described. At first, in order to predict and obtain good efficiency of vibration surveillance within a wide range of spindle speeds, Hardware-In-the-Loop Simulation (HILS), as a mean of mechatronic design, is applied. Subsequently, the predicted results are verified during the real cutting experiment. The latter ones evidenced good performance in the scope of vibration reduction.