Adaptive chatter mitigation control for machining processes with input saturations

Chatter is an unstable nonlinear dynamical phenomenon often encountered in machining operations because of the self‐excitation mechanism, which may lead to overcut or rapid tool wear, and hence, greatly influence the surface quality and productivity in milling operations. Recent years have witnessed an increasing industrial demand of high quality and high efficiency machining. This paper hereby develops a constrained active adaptive control method to mitigate the chatter dynamics with input saturations. To guarantee the feasibility of the proposed approach, moderate stable conditions of the closed‐loop system are afterwards derived by using the LaSalle–Yoshizawa theorem as well. Finally, numerical simulations are conducted to show the substantially enlarged stable region in the Lobe Diagram. Thus, the method can be expected to improve the efficiency of milling processes. Copyright © 2015 John Wiley & Sons, Ltd.