Study on chatter active suppression of robotic rotary ultrasonic machining of large components with poor rigidity

Abstract For the robotic milling of large components with poor rigidity, it is easy to cause machining chatter. Severe chatter reduces the machining accuracy and surface quality of the part and affects the service life of the tool. Currently, the chatter suppression of robotic machining based on ultrasonic machining technology has become a hot topic. In this paper, a chatter active suppression method is proposed by adjusting the input of ultrasonic vibration energy to improve the robotic milling stability. Firstly, according to the optimal ratio of torsional vibration energy to longitudinal vibration energy, the ultrasonic knife handle is designed to improve robotic milling stability. Then, the chatter recognition method is applied to determine whether the robot exhibits chatter. After that, a model for the relationship between ultrasonic vibration energy and chatter energy is constructed for chatter active suppression. Finally, the experiment of robotic rotary ultrasonic milling brackets is carried out. The experimental results indicate that the machining quality meets the requirements of roughness and flatness. Compared with robotic common milling, the machining efficiency could be increased by five times.