Simulation study on the improvements of machining accuracy by using smart materials

This work utilizes smart material to counteract the radial disturbing cutting forces and reduce machining error in the turning process. The finite element method (FEM) is employed to explore the capability of such a method in controlling tool position. Toolpost dynamic response is investigated where the pulse width modulation (PWM) technique is launched for actuator voltage input. The result from tool response using dynamic absorber does not encourage the use of such a vibration attenuator in error elimination in the presence of the PWM voltage input. Even though increasing toolpost damping within a reasonable range shows a reduction in toolpost error, major improvement is noticed by modifying the PWM voltage level and its time duration. For error elimination, the estimate of static actuator voltage does not reflect the actual level of required dynamic applied voltage. This work also emphasizes the importance of tool bit to actuator stiffness and tool carrier (holder) to actuator stiffness in reducing tool positional error.