Machine tool productivity and part surface quality are fundamentally limited by chatter occurring due to regenerative type self-excited vibrations. Efficacy of the existing high-fidelity chatter models to help avoid chatter in real industrial settings remains limited due to the uncertainties in machine tools. To help validate models without the vagaries of the uncertainties and without damaging real machine tool systems, this paper discusses the use of a mechatronic hardware-in-the-loop (HiL) simulator that offers a platform for investigation on chatter. The HiL simulator is a hybrid system of hardware and software components substituting the actual cutting tool-workpiece interaction through an actuator exciting a flexure by an emulated real time cutting force. For the simulator to faithfully represent the physics of the process-machine interactions, experimentally characterized stability behavior with the HiL must necessarily follow model predictions. However, the transfer between the hardware and the software layers of the HiL simulator involves inevitable delays that result in diverging stability behavior. We hence present systematic investigations to identify and compensate the delay in the hardware layer on account of the actuator and the transducers, as well as delays in the software layer on account of signal conditioning. The validated HiL simulator is then used as an experimental platform to investigate the effectiveness of four different control strategies for an active damping system. Being a non-destructive, cost-effective and repeatable platform, the HiL simulator opens up further possibilities for validation of high-fidelity chatter models.

机床生产率和零件表面质量从根本上受到由于再生型自激振动引起的颤振的限制。由于机床的不确定性，现有的高保真颤动模型在实际工业环境中避免颤动的功效仍然有限。为了帮助验证模型而不会造成不确定性的变化，并且不会损坏实际的机床系统，本文讨论了机电一体化硬件在环（HiL）仿真器的使用，该仿真器提供了一个研究颤振的平台。HiL仿真器是硬件和软件组件的混合系统，它通过执行器通过模拟的实时切削力来激发挠曲，从而代替实际的切削工具-工件相互作用。为了使仿真器如实地表示过程-机器交互的物理过程，使用HiL进行实验表征的稳定性必须必须遵循模型预测。但是，HiL仿真器的硬件层和软件层之间的传输涉及不可避免的延迟，从而导致稳定性行为发生分歧。因此，我们目前进行系统研究，以识别和补偿由于执行器和传感器而引起的硬件层延迟，以及由于信号调节而导致的软件层延迟。经过验证的HiL模拟器随后用作实验平台，以研究主动阻尼系统的四种不同控制策略的有效性。作为一个无损，经济高效且可重复的平台，