Milling chatter occurs as undesired vibration in the cutting process, imposing negative effects on the tool’s life, the quality of surface finishes and the limitation of machining efficiency. In this paper, a discrete output feedback robust controller based on linear matrix inequality (LMI) is developed for the chatter suppression, with an electromagnetic actuator applying the needed active control force. Considering the model of electromagnetic actuator and the actual mounting position in the milling system, active milling chatter control system is modeled and discretized for the controller’s design. In addition, uncertainties of model parameters, such as modal parameters, axial cutting depth, are also considered. Then the LMI-based robust controller is designed, with which the performance of active chatter suppression can be guaranteed even the mentioned uncertainties exist in the actual milling system. Simulation results show that the chatter-free boundary of milling process is significantly enlarged with the designed robust controller. An experimental prototype for active milling chatter suppression is also presented, and milling chatter experiments are also performed with the developed spindle system, and the results show that surface finishes and chatter-free boundary are improved significantly.

铣削颤振作为切削过程中的意外振动发生，对刀具寿命、表面光洁度质量和加工效率产生负面影响。在本文中，开发了一种基于线性矩阵不等式 (LMI) 的离散输出反馈鲁棒控制器，用于抑制颤振，电磁致动器施加所需的主动控制力。考虑到电磁执行器的模型和铣削系统中的实际安装位​​置，主动铣削颤振控制系统被建模和离散化用于控制器的设计。此外，还考虑了模态参数、轴向切削深度等模型参数的不确定性。然后设计基于LMI的鲁棒控制器，即使在实际铣削系统中存在上述不确定性，也可以保证主动抑制颤振的性能。仿真结果表明，设计的鲁棒控制器显着扩大了铣削过程的无颤振边界。还提出了一种主动铣削颤振抑制实验样机，并使用开发的主轴系统进行了铣削颤振实验，结果表明表面光洁度和无颤振边界得到了显着改善。