An investigation is undertaken to minimize residual vibrations associated with high-speed, low-amplitude machining processes. A numerically computed input signal allows the system to follow a desired output trajectory once an accurate dynamic model of the system is developed. Specific application of this method is focused on controlling tool motion while cutting micron depth surface features into a flat, rotating workpiece during a single-point diamond turning process. The synthesized input signal, applied open-loop, is used to eliminate transient surface features that are created by uncontrolled motion of the tool when it is plunged into the workpiece surface during the cutting process. Controlled and uncontrolled cuts are shown to demonstrate a significant improvement in resulting surface features. © 1991.
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