Analytical Modeling of Regenerative Chatter Reduction in Milling Using Magneto-Rheological Fluids Actuation by Semi-Active Damping Control

The suppression of regenerative vibrations on machine cutting operations is essential to avoid negative effects on surface finishing, poor machining accuracy and reduction of the tool life. In this paper, we introduce a methodology to reduce the self-excited vibration in milling cutting processes by using magneto-rheological fluids (MR) actuation. The paper provides theoretical analyses of how the MR devices can be used to suppress chatter in conjunction with the Lyapunov's direct and the Linear Quadratic Regulator (LQR) control methods. We solve the resulting delay differential equations by using Chebyshev's pseudo-spectral method and compare the solution with and without control strategies.