Chatter suppression in micro-milling using shank-mounted Two-DOF tuned mass damper |
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| Affiliation: | 1. Department of Industrial Engineering, University of Firenze, Via di Santa Marta 3, 50139, Firenze, Italy;2. Paragon S.A., Karaoli & Dimitriou 13, Athens, Galatsi GR-11146, Greece;1. Key Laboratory of Education Ministry for Modern Design & Rotor-Bearing System, Xi''an Jiaotong University, Xi''an, Shaanxi, China;2. School of Mechanical Engineering, Xi''an Jiaotong University, Xi''an, Shaanxi, China;3. Department of Mechanical Engineering, University of British Columbia, Vancouver, BC, Canada;1. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi''an, Shaanxi 710049, China;2. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi 710049, China;1. Robotics Institute, Beihang University, Beijing 100191, China;2. Department of Mechanical Engineering, University of British Columbia, 2054-6250 Applied Science Lane, Vancouver, BC V6T 1Z4, Canada;3. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China;4. State Key Laboratory of Tribology and Institute of Manufacturing Engineering, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;1. University of Wollongong, Australia;2. Foshan University, China |
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| Abstract: | The tuned mass damper (TMD) has been used in machining processes for reducing forced vibration, suppressing chatter, and improving machined surface quality. In micro-milling process, the tiny size of the cutting tool-tip and the high rotating speed bring challenges in implementing the TMD. Besides, the TMD needs to have two degrees-of-freedom (DOFs) for reducing vibrations of micro-mill in two orthogonal directions. This paper presents the chatter suppression for micro-milling by attaching a two-DOF TMD to the tool shank and rotates with the cutting tool. The frequency response function (FRF) at the tip of the micro-mill clamped by an aerostatic spindle is predicted using receptance coupling analysis. A two-DOF TMD is designed via graphical approach based on the FRF result at the tool-tip. The natural frequencies and damping ratio of the TMD are optimized under different spindle speeds in order to enhance the cutting stability. The chatter stability of micro-milling is predicted considering the gyroscopic and centrifugal effects of the TMD structure. Modal tests and micro-milling experiments are conducted to validate the effect of the TMD on chatter stability. The results show that the TMD is able to improve the critical depth of cut by 13 folds, and satisfy the compact design requirement for micro-milling. |
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| Keywords: | Tuned mass damper Micro-milling Chatter Frequency response function |
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