Proceedings of the ASME 2017 Dynamic Systems and Control Conference DSCC 2017 October 11-13, 2017, Tysons, Virginia, USA DSCC2017-5217 THE DEVELOPMENT OF HIGH SPEED VIRTUAL MILLING TEST Akos Miklos ∗ Denes Takacs MTA-BME Research Group on Dynamics of Machines and Vehicles Budapest University of Technology and Economics Budapest, Hungary Email: miklosa@mm.bme.hu, takacs@mm.bme.hu Richard Wohlfart Gabor Porempovics Tamas G. Molnar Daniel Bachrathy Department of Applied Mechanics Budapest University of Technology and Economics Budapest, Hungary Email: wohl@mm.bme.hu, poremg@mm.bme.hu, molnar@mm.bme.hu, bachrathy@mm.bme.hu Andras Toth Department of Manufacturing Science and Engineering Budapest University of Technology and Economics Budapest, Hungary Email: toth@manuf.bme.hu Gabor Stepan Department of Applied Mechanics Budapest University of Technology and Economics Budapest, Hungary Email: stepan@mm.bme.hu ABSTRACT The concept of a hardware-in-the-loop experiment for high speed milling is introduced in this paper. The tool-workpiece in- teraction is virtually implemented in the experiment while the milling machine with the spindle is used as real element. In this paper, the basic components of the experiment are presented, namely, a contactless displacement sensor, a computational al- gorithm of the cutting force and a contactless electromagnetic actuator are discussed. Experiments on the prototype of the elec- tromagnetic actuator are also shown to illustrate the potential of the concept. A feasibility study of the hardware-in-the-loop ex- periment is given, where the effect of the time delay included in the experiment is investigated. INTRODUCTION One of the most intricate phenomenon of milling is the chat- ter vibration, which usually leads to improper surface quality or ∗ Address all correspondence to this author. in worst case it can also lead to the damage of the milling ma- chine. Theoretical analyses of the models of high speed milling processes aim to predict both the linear stability limits of cut- ting and the so-called unsafe parameter domains in the linearly stable regions where chatter may still occur with certain proba- bility. The industrial applications of these theoretical results are still limited by the availability of extensive laboratory tests re- quired for the validation of the models in case of various working conditions and tool geometries, and also to explore the range of uncertainties of certain parameters. The cost of these tests could be reduced substantially by so-called hardware-in-the-loop (HIL) experiments in which the real tool-workpiece interaction is emu- lated. The reliability of HIL experiments strongly depends on the applied sampling frequency that can be used during the simula- tion and emulation of the cutting forces. For example, the stick- and-slip phenomenon is deeply analyzed in [1], where the asym- metric non-linearity of the Stribeck contact force is similar to that of the cutting force. It is shown in [1] that the HIL experi- 1 Copyright c  2017 by ASME