Dynamic modeling of an internal turning tool using experimental modal analysis and simulation of active vibration control

Due to the high length to diameter of the tool and its high flexibility, internal turning process is very prone to chatter vibrations. Different methods have been used to increase dynamic stiffness of tools; the most effective method is active control method. In order to analyze and design a control system, a dynamic model of the system is required. Obtaining a system model using finite element modeling technique is complicated and time-consuming, thus, a method that can quickly and accurately estimate the response of the vibration control system is very important. The aim of this study is to propose a method for dynamic modeling of the internal turning tool using the experimental modal analysis, which can be used to predict and simulate vibration reduction. In this method, using the experimental modal test, a linear matrix model of the system dynamics was extracted and then the actuator-tool model was identified using sweep frequency method. Thereafter, by using the obtained models, the active vibration control loop of the internal turning tool was simulated in MATLAB/SIMULINK software and the controller performance was investigated. Finally, the simulation results were compared with the experimental results, which indicate good performance of the proposed method for dynamic modeling of the system and controller design. The proposed method in the identification frequency range accurately estimated the system response, and this method can be used to optimize the controller's gain.