Optimization of the Tuned Mass Damper for Chatter Suppression in Turning

The tuned mass damper（TMD） has been successfully applied to the vibration control in machining, while the most widely adopted tuning is equal peaks, which splits the magnitude of the frequency response function（FRF） into equal peaks. However, chatter is a special self-excited problem and a chatter-flee machining is determined by FRF at the cutting zone. A TMD tuning aiming at achieving the maximum chatter stability is studied, and it is formulated as an optimization problem of maximizing the minimum negative real part of FRF. By employing the steepest descend method, the optimum frequency and damping ratio of TMD are obtained, and they are compared against the equal peaks tuning. The advantage of the proposed tuning is demonstrated numerically by comparing the minimum point of the negative real part, and is further verified by damping a flexible mode from the fixture of a turning machine. A TMD is designed and placed on the fixture along the vibration of the target mode after performing modal analysis and mode shape visualization. Both of the above two ttmings are applied to modify the tool point FRF by tuning TMD respectively. Chatter stability chart of the turning shows that the proposed tuning can increase the critical depth of cut 37% more than the equal peaks. Cutting tests with an increasing depth of cut are conducted on the turning machine in order to distinguish the stability limit. The tool vibrations during the machining are compared to validate the simulation results. The proposed damping design and optimization routine are able to further increase the chatter suppression effect.

Chatter suppression techniques in milling processes:A state of the art review

Chatter in the machining system can result in a decrease in tool life,poor surface finish,conservative cutting parameters,etc.Despite many review papers promoting the understanding and research of this area,chatter suppression techniques are generally discussed within limited pages in the framework of comprehensive chatter-related problems.In recent years,the developments of smart materials,advanced sensing techniques,and more effective control strategies have led to some new progress in chatter suppression.Meanwhile,the widely used thin-walled parts present more and more severe machining challenges in their milling processes.Considering the above deficiencies,this paper summarizes the current state of the art in milling chatter suppression.New classifications of chatter suppression techniques are proposed according to the working principle and control target.Based on the new classified framework,the mechanism and comparisons of different chatter suppression strategies are reviewed.Besides,the current challenges and potential tendencies of milling chatter suppression techniques are highlighted.Intellectualization,integration,compactness,adaptability to workpiece geometry,and the collaboration of multiple control methods are predicted to be important trends in the future.

Machining dynamics and chatters in micro-milling:A critical review on the state-of-the-art and future perspectives

Micro-milling technology is widely applied in micro manufacturing,particularly for the fabrication of miniature and micro components.However,the chatters and machining dynamics related issues in micro-milling are often the main challenges restricting its machining quality and productivity.Many research works have rendered that the machining dynamics and chatters in micro-milling are more complex compared with the conventional macro-milling process,likely because of the size effect and rigidity of the micro-milling system including the tooling,workpiece,process variables,materials involved,and the high-speed milling machines,and further their collective dynamic effects.Therefore,in this paper,the state of the art focusing on micro-milling chatters and dynamics related issues over the past years are comprehensively and critically reviewed to provide some insights for potential researchers and practitioners.Firstly,typical applications and the problems caused by the machining dynamics and chatters in micro-milling have been put forward in this paper.Then,the research on the underlying micro-cutting mechanics and dynamics,stability analysis,chatters detection,and chatter suppression are summarized critically.Furthermore,the underlying scientific and technological challenges are discussed particularly against typical precision engineering applications.Finally,the possible future directions and trends in research and development of micro-milling have been discussed.

Stability analysis of robotic longitudinal-torsional composite ultrasonic milling

Currently,industrial robots are considered as an alternative towards traditional machine tools.Especially for the large-scale parts milling,robotic flexibility and low cost make it possess the irreplaceability.However,the milling chatter caused by its weak rigidity hampers robotic application and promotion severely in aviation industry.Rotary ultrasonic milling(RUM)technology with one-dimensional axial vibration has been proven and approved on avoiding robotic chatter.Based on this,the research of project team demonstrates that longitudinal-torsional composite ultrasonic milling(CUM-LT)involving separation characteristic has a greater advantage than RUM in terms of chatter suppression.Thereby,the CUM-LT as a new means is applied to avoid processing vibration of robotic milling system.And its influence mechanism on stability improvement of weak stiffness processing system is clarified.Meanwhile,the approaches to strengthen separation effect are provided innovatively.Moreover,a new analysis method of robotic CUM-LT(RCUM-LT)stability is proposed on the basis of ultrasonic function angles.The simulation and experimental results indicate that compared with robotic RUM(RRUM),stability regions of separated RCUM-LT(SRCUM-LT)and unseparated RCUM-LT(URCUM-LT)are improved by 124.42%and39.20%,respectively.The addition of torsional ultrasonic energy has a wonderful effect on the milling chatter suppression of low stiffness robots.