Optimal Active Chatter Control for Milling Flexible Workpieces Considering Actuator Saturation

Active control methods can be used to improve the chatter stability in milling. However, optimisation of the active control method is vital to obtain the best performance from the controller, especially considering actuator force saturation. Otherwise, the saturation effect can destabilise the controller. In the present paper, an optimisation approach is demonstrated, targeting specific spindle speeds considering the actuator force saturation. A self-adaptive differential evolution algorithm is used for the optimisation process. The predicted results are validated experimentally. It is shown that the stable depth of cut can be improved by a factor up to 13.