Low-order control design for chatter suppression in high-speed milling

Chatter is an instability phenomenon in machining processes which must be avoided at all times. The occurrence of chatter can be predicted using stability lobes diagrams. In this paper a low-order active chatter control design is proposed, which enables dedicated shaping of the chatter stability boundary such that working points of higher machining productivity become feasible while avoiding chatter. The control design problem is cast into a nonsmooth optimization problem, which is solved using bundle methods. A static output feedback controller is designed for an illustrative example, which illustrates the power of the proposed methodology.