Gain-Scheduled Control of Magnetic Bearing Milling Spindles

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This research project is aimed to derive and evaluate control algorithms for rapid adaptation of magnetic bearing dynamics during machining via multivariable gain-scheduling. The tasks include: formulation of models of the spindle and cutting process suitable for development of robust gain-scheduled control algorithms; improvement of the underlying theoretical foundation for the synthesis of gain-scheduled controllers that are capable of modifying the feedback of magnetic bearings for stable cutting; development of numerical tools for the synthesis of gain-scheduled controllers for such systems; evaluation of the resulting control algorithms using numerical simulation of a magnetic bearing milling spindle; and experimental evaluation of gain-scheduled controllers for chatter suppression. This type of magnetic bearing spindle control is unique in that the cutting process is treated as unknown dynamics to which to adapt, rather than an uncertainty with which to robust. The project presents a new and unique approach on magnetic bearing spindle control. The technology, if successfully developed, could result in significantly higher metal removal rates than those achievable by conventional spindles or with the currently available magnetic bearing technology.