Investigation of chatter suppression in slender endmill via a frictional damper

Abstract The main purpose of this paper is to propose a frictional damper so as to enhance structural damping leading to the chatter suppression in the slender endmill tool. The proposed damper is composed of a core press fitted inside a multi-fingered hollow cylinder. Core and cylinder both are press fitted into an axial hole inside the tool. First, an analytical model is developed for the damper. Then, a parameter study is conducted to find optimum parameters of the damper for the increase of the stability limit as much as possible. In order to validate the analytical model, a nonlinear finite element model of the damped milling tool is simulated using ANSYS software package. Having finite element model, the stability lobe diagrams for simple tool and optimally damped tool are extracted from frequency response functions. Modal test is applied to a real specimen of damped tool in order to validate finite element results. Good agreement between experiments and modeling is obtained.

[1]  Keith E. Rouch,et al.  Optimal passive vibration control of cutting process stability in milling , 1991 .

[2]  Etsuo Marui,et al.  Theoretical analysis on chatter vibration in drilling and its suppression , 2003 .

[3]  Min Wang,et al.  Feasibility study of nonlinear tuned mass damper for machining chatter suppression , 2011 .

[4]  Zichen Chen,et al.  Magnetorheological fluid-controlled boring bar for chatter suppression , 2009 .

[5]  Yusuf Altintas,et al.  Analytical Prediction of Stability Lobes in Milling , 1995 .

[6]  Yusuf Altintas,et al.  Optimization of multiple tuned mass dampers to suppress machine tool chatter , 2010 .

[7]  Cornel Mihai Nicolescu,et al.  Design and implementation of tuned viscoelastic dampers for vibration control in milling , 2008 .

[8]  Yuehui Wang.  Advances on Machining Chatter Suppression Research , 2010 .

[9]  Etsuo Marui,et al.  Suppression of chatter vibration of boring tools using impact dampers , 2000 .

[10]  L. N. López de Lacalle,et al.  An automatic spindle speed selection strategy to obtain stability in high-speed milling , 2009 .

[11]  André Preumont,et al.  Simulation and Active Control of Chatter in Milling via a Mechatronic Simulator , 2006 .

[12]  Tetsutaro Hoshi,et al.  Stabilization of high frequency chatter vibration in fine boring by friction damper , 2001 .

[13]  Philip K. Chan,et al.  In-process detection and suppression of chatter in milling , 1992 .

[14]  Soo Hun Lee,et al.  Programming spindle speed variation for machine tool chatter suppression , 2003 .

[15]  K. Palanikumar,et al.  Chatter Suppression in Boring Operation Using Magnetorheological Fluid Damper , 2008 .

[16]  Neil D. Sims,et al.  Vibration absorbers for chatter suppression: A new analytical tuning methodology , 2007 .

[17]  Ken Chen,et al.  Chatter suppression in fast tool servo-assisted turning by spindle speed variation , 2010 .

[18]  John C. Ziegert,et al.  Numerical analysis and parameter study of a mechanical damper for use in long slender endmills , 2006 .

[19]  Ali H. Nayfeh,et al.  Chatter control and stability analysis of a cantilever boring bar under regenerative cutting conditions , 2001, Philosophical Transactions of the Royal Society of London. Series A: Mathematical, Physical and Engineering Sciences.

[20]  H. B. Lacerda,et al.  Evaluation of cutting forces and prediction of chatter vibrations in milling , 2004 .

[21]  T. Schmitz,et al.  Enhanced damping in long slender end mills , 2006 .

[22]  Neil D. Sims,et al.  Optimisation of variable helix tool geometry for regenerative chatter mitigation , 2011 .

[23]  J. Tlusty,et al.  Dynamics of High-Speed Milling , 1986 .

[24]  Bi Zhang,et al.  Chatter Suppression With Multiple Time-Varying Parameters in Turning , 1999, Manufacturing Science and Engineering.

[25]  Min Wang,et al.  Design and implementation of nonlinear TMD for chatter suppression: An application in turning processes , 2010 .

[26]  S. Timoshenko,et al.  Theory of elasticity , 1975 .

[27]  Etsuo Marui,et al.  Plate insertion as a means to improve the damping capacity of a cutting tool system , 1998 .

[28]  H. E. Merritt.  Theory of Self-Excited Machine-Tool Chatter: Contribution to Machine-Tool Chatter Research—1 , 1965 .

[29]  Natarajan Shankar,et al.  Mitigation of chatter instabilities in milling by active structural control , 2001 .

[30]  S. E. Semercigil,et al.  Preliminary computations for chatter control in end milling , 2002 .