Chatter Stability Characterization of Full-Immersion End-Milling Using a Generalized Modified Map of the Full-Discretization Method, Part 1: Validation of Results and Study of Stability Lobes by Numerical Simulation

The objective in this work is to generate and discuss the stability results of fully-immersed end-milling process with parameters; tool mass m=0.0431kg,tool natural frequency ωn = 5700 rads^-1, damping factor ξ=0.002 and workpiece cutting coefficient C=3.5x10^7 Nm^-7/4. Different no of teeth is considered for the end-milling. Both 1-DOF and 2-DOF chatter models of the system are generated on the basis of non-linear force law. Chatter stability analysis is carried out using a modified form (generalized for both 1-DOF and 2-DOF models) of recently developed method called Full-discretization. The full-immersion three tooth end-milling together with higher toothed end-milling processes has secondary Hopf bifurcation lobes (SHBL’s) that exhibit one turning (minimum) point each. Each of such SHBL is demarcated by its minimum point into two portions; (i) the Lower Spindle Speed Portion (LSSP) in which bifurcations occur in the right half portion of the unit circle centred at the origin of the complex plane and (ii) the Higher Spindle Speed Portion (HSSP) in which bifurcations occur in the left half portion of the unit circle. Comments are made regarding why bifurcation lobes should generally get bigger and more visible with increase in spindle speed and why flip bifurcation lobes (FBL’s) could be invisible in the low-speed stability chart but visible in the high-speed stability chart of the fully-immersed three-tooth miller.

Low Value Capacitance Measurement System with Adjustable Lead Capacitance Compensation

The present paper describes the development of a low cost, highly accurate low capacitance measurement system that can be used over a range of 0 – 400 pF with a resolution of 1 pF. The range of capacitance may be easily altered by a simple resistance or capacitance variation of the measurement circuit. This capacitance measurement system uses quad two-input NAND Schmitt trigger circuit CD4093B with hysteresis for the measurement and this system is integrated with PIC 18F2550 microcontroller for data acquisition purpose. The microcontroller interacts with software developed in the PC end through USB architecture and an attractive graphical user interface (GUI) based system is developed in the PC end to provide the user with real time, online display of capacitance under measurement. The system uses a differential mode of capacitance measurement, with reference to a trimmer capacitance, that effectively compensates lead capacitances, a notorious error encountered in usual low capacitance measurements. The hysteresis provided in the Schmitt-trigger circuits enable reliable operation of the system by greatly minimizing the possibility of false triggering because of stray interferences, usually regarded as another source of significant error. The real life testing of the proposed system showed that our measurements could produce highly accurate capacitance measurements, when compared to cutting edge, high end digital capacitance meters.

Design of Adaptive Sliding Mode Controller for Robotic Manipulators Tracking Control

This paper proposes an adaptive sliding mode controller which combines adaptive control and sliding mode control to control a nonlinear robotic manipulator with uncertain parameters. We use an adaptive algorithm based on the concept of sliding mode control to alleviate the chattering phenomenon of control input. Adaptive laws are developed to obtain the gain of switching input and the boundary layer parameters. The stability and convergence of the robotic manipulator control system are guaranteed by applying the Lyapunov theorem. Simulation results demonstrate that the chattering of control input can be alleviated effectively. The proposed controller scheme can assure robustness against a large class of uncertainties and achieve good trajectory tracking performance.

Fuzzy Sliding Mode Control of an MR Mount for Vibration Attenuation

In this paper, an magnetorheological (MR) mount with fuzzy sliding mode controller (FSMC) is studied for vibration suppression when the system is subject to base excitations. In recent years, magnetorheological fluids are becoming a popular material in the field of the semi-active control. However, the dynamic equation of an MR mount is highly nonlinear and it is difficult to identify. FSMC provides a simple method to achieve vibration attenuation of the nonlinear system with uncertain disturbances. This method is capable of handling the chattering problem of sliding mode control effectively and the fuzzy control rules are obtained by using the Lyapunov stability theory. The numerical simulations using one-dimension and two-dimension FSMC show effectiveness of the proposed controller for vibration suppression. Further, the well-known skyhook control scheme and an adaptive sliding mode controller are also included in the simulation for comparison with the proposed FSMC.

Effect of Heat Treatment on the Portevin-Le Chatelier Effect of Al-2.5%Mg Alloy

An experimental study is presented on the effect of microstructural change on the Portevin-Le Chatelier effect behaviour of Al-2.5%Mg alloy. Tensile tests are performed on the as received and heat treated (at 400 ºC for 16 hours) samples for a wide range of strain rates. The serrations observed in the stress-time curve are investigated from statistical analysis point of view. Microstructures of the samples are characterized by optical metallography and X-ray diffraction. It is found that the excess vacancy generated due to heat treatment leads to decrease in the strain rate sensitivity and the increase in the number of stress drop occurrences per unit time during the PLC effect. The microstructural parameters like domain size, dislocation density have no appreciable effect on the PLC effect as far as the statistical behavior of the serrations is considered.

Finite Element Prediction on the Machining Stability of Milling Machine with Experimental Verification

Chatter vibration has been a troublesome problem for a machine tool toward the high precision and high speed machining. Essentially, the machining performance is determined by the dynamic characteristics of the machine tool structure and dynamics of cutting process, which can further be identified in terms of the stability lobe diagram. Therefore, realization on the machine tool dynamic behavior can help to enhance the cutting stability. To assess the dynamic characteristics and machining stability of a vertical milling system under the influence of a linear guide, this study developed a finite element model integrated the modeling of linear components with the implementation of contact stiffness at the rolling interface. Both the finite element simulations and experimental measurements reveal that the linear guide with different preload greatly affects the vibration behavior and milling stability of the vertical column spindle head system, which also clearly indicate that the predictions of the machining stability agree well with the cutting tests. It is believed that the proposed model can be successfully applied to evaluate the dynamics performance of machine tool systems of various configurations.

Design of Moving Sliding Surfaces in A Variable Structure Plant and Chattering Phenomena

This paper deals with the design of a moving sliding surface in a variable structure plant for a second order system. The chattering phenomena is also dealt with during the switching process for an unstable sliding surface condition. The simulation examples considered in this paper shows the effectiveness of the sliding mode control method used for the design of the moving sliding surfaces. A simulink model of the continuous system was also developed in MATLAB-SIMULINK for the design and hence demonstrated. The phase portraits and the state plots shows the demonstration of the powerful control technique which can be applied for second order systems.

Analysis of Chatter in Ball End Milling by Wavelet Transform

The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the new three parameters are introduced from three dynamic cutting forces, which are calculated by taking the ratio of the average variances of dynamic cutting forces to the absolute variances of themselves. It had been proved that the chatter can be easier to detect during the in-process cutting by using the new parameters which are proposed in this research. The experimentally obtained results showed that the wavelet transform can provide the reliable results to detect the chatter under various cutting conditions.

Chaos-based Secure Communication via Continuous Variable Structure Control

The design of chaos-based secure communication via synchronized modified Chua-s systems is investigated in this paper. A continuous control law is proposed to ensure synchronization of the master and slave modified Chua-s systems by using the variable structure control technique. Particularly, the concept of extended systems is introduced such that a continuous control input is obtained to avoid chattering phenomenon. Then, it becomes possible to ensure that the message signal embedded in the transmitter can be recovered in the receiver.

Asymptotic Stabilization of an Active Magnetic Bearing System using LMI-based Sliding Mode Control

In this paper, stabilization of an Active Magnetic Bearing (AMB) system with varying rotor speed using Sliding Mode Control (SMC) technique is considered. The gyroscopic effect inherited in the system is proportional to rotor speed in which this nonlinearity effect causes high system instability as the rotor speed increases. Also, transformation of the AMB dynamic model into a new class of uncertain system shows that this gyroscopic effect lies in the mismatched part of the system matrix. Moreover, the current gain parameter is allowed to be varied in a known bound as an uncertainty in the input matrix. SMC design method is proposed in which the sufficient condition that guarantees the global exponential stability of the reduced-order system is represented in Linear Matrix Inequality (LMI). Then, a new chattering-free control law is established such that the system states are driven to reach the switching surface and stay on it thereafter. The performance of the controller applied to the AMB model is demonstrated through simulation works under various system conditions.

Trajectory Control of a Robotic Manipulator Utilizing an Adaptive Fuzzy Sliding Mode

In this paper, a novel adaptive fuzzy sliding mode control method is proposed for the robust tracking control of robotic manipulators. The proposed controller possesses the advantages of adaptive control, fuzzy control, and sliding mode control. First, system stability and robustness are guaranteed based on the sliding mode control. Further, fuzzy rules are developed incorporating with adaptation law to alleviate the input chattering effectively. Stability of the control system is proven by using the Lyapunov method. An application to a three-degree-of-freedom robotic manipulator is carried out. Accurate trajectory tracking as well as robustness is achieved. Input chattering is greatly eliminated.

Efficient CNC Milling by Adjusting Material Removal Rate

This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining vibration, and chatter. Case studies reveal the fact that application of this approach could result in a slight increase of machining time, however, a considerable reduction of tooling cost, machining vibration, noise and chatter can be achieved in addition to producing a better surface finish.

Experimental Investigation of Chatter Vibrations in Facing and Turning Processes

This paper investigates the occurrence of regenerative chatter vibrations in facing and turning processes. Orthogonal turning (facing) and normal turning experiments are carried out under stable as well as in the presence of controlled chatter vibrations. The effects of chatter vibrations on various sensor signals are captured and analyzed using frequency domain methods, which successfully detected the chatter vibrations close to the dominant mode of the machine tool system.

A Black-box Approach for Response Quality Evaluation of Conversational Agent Systems

The evaluation of conversational agents or chatterbots question answering systems is a major research area that needs much attention. Before the rise of domain-oriented conversational agents based on natural language understanding and reasoning, evaluation is never a problem as information retrieval-based metrics are readily available for use. However, when chatterbots began to become more domain specific, evaluation becomes a real issue. This is especially true when understanding and reasoning is required to cater for a wider variety of questions and at the same time to achieve high quality responses. This paper discusses the inappropriateness of the existing measures for response quality evaluation and the call for new standard measures and related considerations are brought forward. As a short-term solution for evaluating response quality of conversational agents, and to demonstrate the challenges in evaluating systems of different nature, this research proposes a blackbox approach using observation, classification scheme and a scoring mechanism to assess and rank three example systems, AnswerBus, START and AINI.

Milling Chatter Prevention by Adaptive Spindle Speed Tuning

This paper presents how the real-time chatter prevention can be realized by feedback of acoustic cutting signal, and the efficacy of the proposed adaptive spindle speed tuning algorithm is verified by intensive experimental simulations. A pair of microphones, perpendicular to each other, is used to acquire the acoustic cutting signal resulting from milling chatter. A real-time feedback control loop is constructed for spindle speed compensation so that the milling process can be ensured to be within the stability zone of stability lobe diagram. Acoustic Chatter Signal Index (ACSI) and Spindle Speed Compensation Strategy (SSCS) are proposed to quantify the acoustic signal and actively tune the spindle speed respectively. By converting the acoustic feedback signal into ACSI, an appropriate Spindle Speed Compensation Rate (SSCR) can be determined by SSCS based on real-time chatter level or ACSI. Accordingly, the compensation command, referred to as Added-On Voltage (AOV), is applied to increase/decrease the spindle motor speed. By inspection on the precision and quality of the workpiece surface after milling, the efficacy of the real-time chatter prevention strategy via acoustic signal feedback is further assured.

Sliding Mode Control with Fuzzy Boundary Layer to Air-Air Interception Problem

The performance of a type of fuzzy sliding mode control is researched by considering the nonlinear characteristic of a missile-target interception problem to obtain a robust interception process. The variable boundary layer by using fuzzy logic is proposed to reduce the chattering around the switching surface then is applied to the interception model which was derived. The performances of the sliding mode control with constant and fuzzy boundary layer are compared at the end of the study and the results are evaluated.

Fuzzy Sliding Mode Speed Controller for a Vector Controlled Induction Motor

This paper presents a speed fuzzy sliding mode controller for a vector controlled induction machine (IM) fed by a voltage source inverter (PWM). The sliding mode based fuzzy control method is developed to achieve fast response, a best disturbance rejection and to maintain a good decoupling. The problem with sliding mode control is that there is high frequency switching around the sliding mode surface. The FSMC is the combination of the robustness of Sliding Mode Control (SMC) and the smoothness of Fuzzy Logic (FL). To reduce the torque fluctuations (chattering), the sign function used in the conventional SMC is substituted with a fuzzy logic algorithm. The proposed algorithm was simulated by Matlab/Simulink software and simulation results show that the performance of the control scheme is robust and the chattering problem is solved.

PI Controller for Automatic Generation Control Based on Performance Indices

The optimal design of PI controller for Automatic Generation Control in two area is presented in this paper. The concept of Dual mode control is applied in the PI controller, such that the proportional mode is made active when the rate of change of the error is sufficiently larger than a specified limit otherwise switched to the integral mode. A digital simulation is used in conjunction with the Hooke-Jeeve’s optimization technique to determine the optimum parameters (individual gain of proportional and integral controller) of the PI controller. Integrated Square of the Error (ISE), Integrated Time multiplied by Absolute Error(ITAE) , and Integrated Absolute Error(IAE) performance indices are considered to measure the appropriateness of the designed controller.  The proposed controller are tested for a two area single nonreheat thermal system considering the practical aspect of the problem such as Deadband and Generation Rate Constraint(GRC). Simulation results show that  dual mode with optimized values of the gains improved the control performance than the commonly used Variable Structure .

Robust Position Control of an Electromechanical Actuator for Automotive Applications

In this paper, the position control of an electronic throttle actuator is outlined. The dynamic behavior of the actuator is described with the help of an uncertain plant model. This motivates the controller design based on the ideas of higher-order slidingmodes. As a consequence anti-chattering techniques can be omitted. It is shown that the same concept is applicable to estimate unmeasureable signals. The control law and the observer are implemented on an electronic control unit. Results achieved by numerical simulations and real world experiments are presented and discussed.

RADAR Imaging to Develop an Enhanced Fog Vision System for Collision Avoidance

The scattering effect of light in fog improves the difficulty in visibility thus introducing disturbances in transport facilities in urban or industrial areas causing fatal accidents or public harassments, therefore, developing an enhanced fog vision system with radio wave to improvise the way outs of these severe problems is really a big challenge for researchers. Series of experimental studies already been done and more are in progress to know the weather effect on radio frequencies for different ranges. According to Rayleigh scattering Law, the propagating wavelength should be greater than the diameter of the particle present in the penetrating medium. Direct wave RF signal thus have high chance of failure to work in such weather for detection of any object. Therefore an extensive study was required to find suitable region in the RF band that can help us in detecting objects with proper shape. This paper produces some results on object detection using 912 MHz band with successful detection of the persistence of any object coming under the trajectory of a vehicle navigating in indoor and outdoor environment. The developed images are finally transformed to video signal to enable continuous monitoring.