Enhanced chatter control in milling with electromagnetic actuator embedded in the tool holder

Milling chatter, a significant impediment to machining efficiency, adversely affects tool life and workpiece quality. To address this problem, this study presents a novel control method based on the embedded electromagnetic actuator (EMA) in the tool holder. By integrating a displacement sensor with the EMA, a comprehensive active control structure is established. System modeling and mechatronic modeling follow. Based on the results of the sweep experiments, a PD controller with optimal phase compensation is designed. During operation, this controller detects the vibration displacement of the tool holder and dampens its weak modes, thereby managing the chatter frequency. The method is validated by numerical simulations using impact and milling force identification test data. In addition, two milling experiments demonstrated the effectiveness of the method. Spindle-tool system chatter was significantly reduced, resulting in improved machining quality. In conclusion, our proposed structure and control strategy offers a powerful remedy to the challenges of milling chatter.