Analysis of Cutting Tool-Workpiece System with PID Controller

The objective is to develop a two degree of freedom model with PID Controller for turning process to reduce regenerative chatter with the aim of improving productivity, quality of surface finish, tool life and reducing environmental noise caused by chatter. A system model consisting of a workpiece subsystem (workpiece with end supports represented by mass, stiffness, damping coefficient) and a cutting tool subsystem (tool with its supports represented by mass, stiffness and the damping coefficient). A Mechatronic system has been proposed and developed for reducing tool vibration in lathe tool during machining. It consists of electrical and mechanical components;the controller is designed to control the chatter that occurs between the tool and the workpiece. A Piezo actuator and sensor was embedded into the tool holder. The controller is used to send a feedback to the actuator. The Controller is to be designed so that it suppresses the settling time and dampens the tool. The effective cutting stiffness and effective cutting damping are modelled as a spring and damper during machining. The original response of the system is modelled using transfer function method. Their output responses were obtained using Mat lab software.