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Since robot’s structural stiffness is usually less than 1 N/µm, mode coupling chatter occurs frequently during robotic milling process, and chatter frequency is close to the natural frequency of the robot itself. Chatter not only affects the surface quality but also damages the robot and reduces the positioning accuracy. Therefore, it is necessary to predict chatter in robotic machining process.

A three-dimensional dynamic model for robot’s spatial milling plane is established, and a corresponding stability criterion is obtained. First, the cutting force in milling plane is transformed into the coordinate system of the robot principal stiffness direction based on homogeneous transformation matrix. Then the three-dimensional stability criterion under milling process can be obtained by using system stability analysis. Furthermore, the circle diagram of mode coupling chatter stability is drawn. Each feeding direction’s stability under the two processing forms, referred as spindle vertical milling and spindle horizontal milling, is analyzed.

The experimental results verify that the three-dimensional stability criterion can avoid chatter by selecting machining feed direction in stable area.

This paper established a three-dimensional dynamic model in robot’s spatial milling plane and proposed a three-dimensional stability criterion according to the Routh criterion. The work is also expected to be an efficient tool in the development of robotic milling technology.

Compared with the high stiffness of traditional CNC machine tools, the structural stiffness of industrial robots is usually less than 1 N/µm. Chatter not only affects the quality of robotic milling but also reduces the accuracy of the milling process. The purpose of this paper is to reduce chatter in the robotic machining process.

First, the mode coupling chatter mechanism is analyzed. Then the milling force model and the principal stiffness model are established. Finally, the robot milling stability optimization method is proposed. The method considered functional redundancies, and a new robot milling stability index is proposed to improve the quality of milling operations.

The experimental results prove a significant reduction in force fluctuations and surface roughness after using the proposed robotic milling stability optimization method.

In this paper, a new robot milling stability index and a new robot milling stability optimization method are proposed. This method can significantly increase the milling stability and improve the milling quality, which can be widely used in the industry.

A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of the service period of the cutting tool while machining. It is significant to provide a corresponding real-time varying damping to control this chatter, which directly influences accuracy and quality of productivity. This paper aims to review the literature related to the application of smart fluid to control vibration in metal cutting and also focused on the challenges involved in the implementation of active control system during machining process.

Smart dampers, which are used as semi-active and active dampers in metal cutting, were reviewed and the research studies carried out in the field of the magnetorheological (MR) damper were concentrated. In smart materials, MR fluids possess some disadvantages because of their sedimentation of iron particles, leakage and slow response time. To overcome these drawbacks, new MR materials such as MR foam, MR elastomers, MR gels and MR plastomers have been recommended and suggested. This review intents to throw light into available literature which exclusively deals with controlling chatter in metal cutting with the help of MR damping methods.

Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. In the past, many researchers have attempted to implement MR damper in metal cutting to control vibration and were successful. Various methods with the help of MR fluid are illustrated.

A new cutting tool is always well-defined and sharp at the onset of metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of service period of cutting tool while machining. Application of MR damper along with the working methodology in metal cutting is presented, challenges met are analyzed and a scope for development is reviewed.

This study provides corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity. Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration.

This study attempts to implement smart damper in metal cutting to control vibrations.

It is significant to provide corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity.

This paper aims to present the critical issues and methodologies to improve robotic machining performance with flexile industrial robots.

A complete solution using active force control is introduced to address various issues during the robotic machining process.

Programming complex couture parts without a CAD model is made easy by using force control functions such as lead‐through and path‐learning. The problem of process control is treated with a novel methodology that consists of stiffness modeling, real‐time deformation compensation for quality and controlled material removal rate for process efficiency.

Experimental results showed that higher productivity as well as better surface quality can be achieved, indicating a promising and practical use of industrial robots for machining applications that is not available at present.

Recent research has considered robotic machining as a dextrous alternative to traditional CNC machine tools for complex sculptured surfaces. One challenge in using robotic machining is that the stiffness is lower than traditional machine tools, due to the cantilever design of the links and low‐torsional stiffness of the actuators. This paper seeks to examine this limitation, using optimization algorithms to determine the best trajectories for the manipulators such that the stiffness is maximized.

The issue of low stiffness is addressed with an integrated off‐line planner and real‐time re‐planner. The available manipulator stiffness is maximized during off‐line planning through a trajectory resolution method that exploits the nullspace of the robot machining system. In response to unmodeled disturbances, a real‐time trajectory re‐planner utilizes a time‐scaling method to reduce the tool speed, thereby reducing the demand on the actuator torques, increasing the robot's dynamic stiffness capabilities. During real‐time re‐planning, priorities are assigned to conflicting performance criteria such as stiffness, collision avoidance, and joint limits.

The algorithms developed were able to generate trajectories with stiffer configurations, which resulted in a reduction in the actuator torques. The real‐time re‐planner successfully allowed the process plan to continue when disturbances were encountered.

Simulations are presented to demonstrate the effectiveness of the approach.

Addressing the limitation of stiffness in serial‐link manipulators will enable robots to become more suitable for machining tasks. The real‐time re‐planning approach will allow robots to become more autonomous during the execution of a given task.

An integrated off‐line and real‐time planning approach has been applied to robotic machining.

This paper aims to solve the problems of the synchronization between branches and the uncertainties such as joint friction, load variation and external interference of a hybrid mechanism. The controller is used to improve the synchronization and robustness of the hybrid mechanism system and achieve both finite time convergence and chattering-free sliding mode.

First, the dynamic model of hybrid mechanism containing lumped uncertainties is formulated by the Lagrange method, and a composite error based on coupling synchronization error and the end-effector tracking error is set up in the task space. Then, by combining the finite time super twisting sliding mode control algorithm, a composite error-based finite time super twisting sliding mode synchronous control law is designed to make the end-effector tracking error and coupling synchronization error achieve better tracking performance and convergence performance. Finally, the Lyapunov stability of the control law and the finite-time convergence of the composite error are proved theoretically.

To verify the effectiveness of the proposed control method, simulations and experiments for the prototype system of the hybrid mechanism are conducted. The results show that the proposed control method can achieve better tracking performance and convergence performance.

This is a new innovation for a hybrid mechanism containing lumped uncertainties to improve the robustness, convergence performance, tracking performance and synchronization of the system.

To facilitate the nonlinear controller design, dynamic model of a novel coaxial unmanned helicopter (UH) is established and its coupling analysis is presented.

The chattering-free sliding mode controller (SMC) with unidirectional auxiliary surfaces (UASs) is designed and implemented for the coaxial ducted fan UH.

The coupling analysis based on the established model show severe coupling between channels. For coaxial UH’s special model structure, UAS-SMC controller is proposed to reduce the coupling characteristics between channels of the UH by setting controllers’ output calculation sequence.

The flight control law and control logic are successfully tested in numerical simulation and hardware in the loop (HIL) simulation. The results show best hovering performances without chattering problem, even under the bounded internal dynamics and external disturbances.

The purpose of this paper is to present a sliding mode attitude controller for reusable launch vehicle (RLV) which is nonlinear, coupling, and includes uncertain parameters and external disturbances.

A smooth second-order nonsingular terminal sliding mode (NTSM) controller is proposed for RLV in reentry phase. First, a NTSM manifold is proposed for finite-time convergence. Then a smooth second sliding mode controller is designed to establish the sliding mode. An observer is utilized to estimate the lumped disturbance and the estimation result is used for feedforward compensation in the controller.

It is mathematically proved that the proposed sliding mode technique makes the attitude tracking errors converge to zero in finite time and the convergence time is estimated. Simulations are made for RLV through the assumption that aerodynamic parameters and atmospheric density are perturbed. Simulation results demonstrate that the proposed control strategy is effective, leading to promising performance and robustness.

By the proposed controller, the second-order sliding mode is established. The attitude tracking error converges to zero in a finite time. Meanwhile, the chattering is alleviated and a smooth control input is obtained.

The purpose of this paper is to propose a combination bank-to-turn control mode with the single moving mass and reaction jet and design the roll control law for the long-range reentry maneuverable warhead.

Based on the dynamics model of this new control mode, the control model of roll channel is converted into a perturbed double-integrator system. The on-off optimal feedback control law is designed on the phase plane formed by Euler angle error and angular velocity error. To weaken the “on-off chattering” that is generated near the origin of the phase-plane and effectively reduce the jet fuel consumption for stability control, an on-off control outer ring and an inner ring are introduced into the phase plane.

This control mode can not only avoid the aerodynamic rudder ablation to improve the efficiency of attitude control, but also reduce the fuel consumption of jet control by using moving mass control. The simulation results indicate that the designed control law can meet the speediness and robustness requirements of the long-range maneuverable warhead controlled by the single moving mass and reaction jet. This measure can also eliminate the on-off chattering effectively.

The new control mode solves some engineering problems of long-range reentry maneuverable warhead controlled by only one actuator. The control mode has a promising prospect in engineering practice.

The paper provides a new control mode and a combination control strategy, and designs an effective control law.

A welding robot is a complicated system with uncertainty, time-varying, strong coupling and non-linear system. It is more complicated if it is used in an underwater environment. It is difficult to establish an accurate dynamic model for an underwater welding robot. Aiming at the tracking control of an underwater welding robot, it is difficult to achieve the control performance requirements by the classical proportional integral derivative control method to realize automatic tracking of the seam. The purpose of this paper is to suggest a novel method to deal with these issues.

To combine the advantages of active disturbance rejection control (ADRC) and sliding mode control (SMC) to improve the shortcomings of a single control method, a hybrid control method for an underwater welding robot trajectory tracking based on SMC_ADRC is proposed in this research work.

The simulation experiment of the proposed approach is carried out by Matlab/Simulink, and the welding experiment is recorded. The seam gets plumper and smoother, with better continuity and no undercut phenomenon.

The proposed approach is effective and reliable, and the system’s tracking performance is stable, which can effectively reduce chattering and improve system robustness.