Numerical Solution of Tuned Mass Dampers for Optimum Milling Chatter Suppression

2011 ◽  
Vol 697-698 ◽  
pp. 223-228
Author(s):  
Yi Qing Yang ◽  
T.T. Chen
Keyword(s):  
Vibration Suppression ◽  
Numerical Approach ◽  
Harmonic Excitation ◽  
Complex Problem ◽  
Depth Of Cut ◽  
Tuned Mass Dampers ◽  
Chatter Suppression ◽  
Machine Tool Chatter ◽  
Chatter Control ◽  
Milling Chatter

The most common tunings for the TMD in the field of vibration suppression are H∞ and H2. However, regenerative machine tool chatter is a complex problem with many variations, which therefore requires a new tuning for the optimum chatter suppression. The real part based tuning is investigated numerically by employing the minimax numerical approach, which aims to maximize the minimum real part of the primary structure under the harmonic excitation. The performances of multiple TMDs system are discussed. A face milling case is employed to verify the benefits of multiple TMDs in increasing the chatter free depth of cut. It is concluded that multiple TMDs configuration are more effective than single TMD in chatter control.

Chatter Suppression in Milling: An Active Approach

1999 ◽  
Author(s):  
Douglas R. Browning ◽  
Igor Golioto ◽  
Norman B. Thompson
Keyword(s):  
The Body ◽  
Active System ◽  
Tool Holder ◽  
Chatter Suppression ◽  
Cutting Test ◽  
Active Approach ◽  
Chatter Control ◽  
Control Electronics ◽  
Drive Signals ◽  
Milling Chatter

Abstract A new approach to chatter control in milling is presented in this paper. The proof-of-concept control system comprises a tool holder, analog and digital control electronics, and power amplifiers to drive the actuator elements. The active tool holder, designed to impart counter-vibration forces to the milling tool, mounts to existing machines with a standard industrial interface. Sensors and piezoelectric actuators are imbedded in the stationary portion of the tool holder and are therefore fixed relative to the body of the milling machine. The controller operates on the two sensor signals, producing two orthogonal actuator drive signals to oppose resonant tool vibrations induced from the cutting forces. The paper first introduces the fundamental concepts of milling chatter and their relation to the described active system. The actuation, sensing and controller details follow. The influence of the tool holder on system dynamics and cutting stability is also addressed. Cutting test results using a titanium alloy are then described, demonstrating an improvement of a factor of five in surface finish relative to the uncontrolled, chatter-dominated case.

scholarly journals Design of eddy current dampers for vibration suppression in robotic milling

2018 ◽  
Vol 10 (11) ◽  
pp. 168781401881407 ◽  
Author(s):  
Fan Chen ◽  
Huan Zhao
Keyword(s):  
Eddy Current ◽  
Vibration Suppression ◽  
Milling Process ◽  
Magnetic Flux Density ◽  
Depth Of Cut ◽  
Chatter Suppression ◽  
Robotic Milling ◽  
Eddy Current Damper ◽  
Damper Design ◽  
Milling Robot

The milling robot normally has a low stiffness which may easily cause chatter during machining. This article presents a novel eddy current damper design for chatter suppression in the robotic milling process. The designed eddy current dampers are installed on the milling spindle to damp the tool tip vibrations. The structural design and the working principle of the eddy current dampers are explained. The magnetic flux density distribution and the magnetic force generation of the designed eddy current damper are analyzed with the finite element method. The tool tip dynamics without and with eddy current dampers are modeled, and the damping performance of the proposed eddy current dampers in the robotic milling process is verified through both simulations and experiments. The results show that the peaks of the tool tip frequency response function caused by the milling tool modes are damped significantly, and the stable depth of cut is improved greatly with eddy current dampers.

Numerical investigation of chatter suppression in milling using active fixtures in open-loop control

2016 ◽  
Vol 24 (9) ◽  
pp. 1757-1773 ◽  
Author(s):  
Lorenzo Sallese ◽  
Niccolò Grossi ◽  
Antonio Scippa ◽  
Gianni Campatelli
Keyword(s):  
Numerical Investigation ◽  
Removal Rate ◽  
Active Vibration Control ◽  
Open Loop ◽  
Influential Factors ◽  
Depth Of Cut ◽  
Control Logic ◽  
Loop Control ◽  
Testing Environment ◽  
Chatter Suppression

Among the chatter suppression techniques in milling, active fixtures seem to be the most industrially oriented, mainly because these devices could be directly retrofittable to a variety of machine tools. The actual performances strongly depend on fixture design and the control logic employed. The usual approach in the literature, derived from general active vibration control applications, is based on the employment of adaptive closed-loop controls aimed at mitigating the amplitude of chatter frequencies with targeted counteracting vibrations. Whilst this approach has proven its effectiveness, a general application would demand a wide actuation bandwidth that is practically impeded by inertial forces and actuator-related issues. This paper presents the study of the performance of alternative open-loop actuation strategies in suppressing chatter phenomena, aiming at limiting the required actuation bandwidth. A dedicated time-domain simulation model, integrating fixture dynamics and the features of piezoelectric actuators, is developed and experimentally validated in order to be used as a testing environment to assess the effectiveness of the proposed actuation strategies. An extensive numerical investigation is then carried out to highlight the most influential factors in assessing the capability of suppressing chatter vibrations. The results clearly demonstrated that the regenerative effect could be effectively disrupted by actuation frequencies close to half the tooth-pass frequency, as long as adequate displacement is provided by the actuators. This could sensibly increase the critical axial depth of cut and hence improve the achievable material removal rate, as discussed in the paper.

The Two-Degree-of-Freedom Tuned-Mass Damper for Suppression of Single-Mode Vibration Under Random and Harmonic Excitation

2005 ◽  
Vol 128 (1) ◽  
pp. 56-65 ◽  
Author(s):  
Lei Zuo ◽  
Samir A. Nayfeh
Keyword(s):  
Vibration Suppression ◽  
Single Mode ◽  
Tuned Mass Damper ◽  
Harmonic Excitation ◽  
Degree Of Freedom ◽  
Primary System ◽  
H Infinity ◽  
Mass Damper ◽  
Mode Vibration ◽  
Two Degree Of Freedom

Whenever a tuned-mass damper is attached to a primary system, motion of the absorber body in more than one degree of freedom (DOF) relative to the primary system can be used to attenuate vibration of the primary system. In this paper, we propose that more than one mode of vibration of an absorber body relative to a primary system be tuned to suppress single-mode vibration of a primary system. We cast the problem of optimization of the multi-degree-of-freedom connection between the absorber body and primary structure as a decentralized control problem and develop optimization algorithms based on the H2 and H-infinity norms to minimize the response to random and harmonic excitations, respectively. We find that a two-DOF absorber can attain better performance than the optimal SDOF absorber, even for the case where the rotary inertia of the absorber tends to zero. With properly chosen connection locations, the two-DOF absorber achieves better vibration suppression than two separate absorbers of optimized mass distribution. A two-DOF absorber with a negative damper in one of its two connections to the primary system yields significantly better performance than absorbers with only positive dampers.

Nonlinear Normal Modes of a Continuous Cantilever Beam with Nonlinear Energy Sink Absorber

2013 ◽  
Vol 325-326 ◽  
pp. 214-217
Author(s):  
Yong Chen ◽  
Yi Xu
Keyword(s):  
Cantilever Beam ◽  
Vibration Suppression ◽  
Normal Modes ◽  
Nonlinear Energy Sink ◽  
Nonlinear Normal Modes ◽  
Harmonic Excitation ◽  
Energy Sink ◽  
Nonlinear Normal ◽  
Nonlinear Energy ◽  
Good Agreement

Using nonlinear energy sink absorber (NESA) is a good countermeasure for vibration suppression in wide board frequency region. The nonlinear normal modes (NNMs) are helpful in dynamics analysis for a NESA-attached system. Being a primary structure, a cantilever beam whose modal functions contain hyperbolic functions is surveyed, in case of being attached with NESA and subjected to a harmonic excitation. With the help of Galerkins method and Raushers method, the NNMs are obtained analytically. The comparison of analytical and numerical results indicates a good agreement, which confirms the existence of the nonlinear normal modes.

Back-iron design-based electromagnetic regenerative tuned mass damper

2020 ◽  
Vol 234 (3) ◽  
pp. 607-622
Author(s):  
Semen Kopylov ◽  
Zhaobo Chen ◽  
Mohamed AA Abdelkareem
Keyword(s):  
Root Mean Square ◽  
Tuned Mass Damper ◽  
Harmonic Excitation ◽  
Experimental Results ◽  
Mean Square ◽  
Tuned Mass Dampers ◽  
Practical Applications ◽  
Mass Damper ◽  
Compact Dimension ◽  
Regenerative Power

Implementation of tuned mass dampers is the commonly used approach to avoid excessive vibrations in civil engineering. However, due to the absence of the compact dimension, there are still no practical applications of the tuned mass dampers in automotive industry. Meanwhile, recent investigations showed the benefit of utilizing a tuned mass damper in a vehicle suspension in terms of driving comfort and road holding. Thus, the current investigation aimed to explore a novel compact dimension tuned mass damper, which can provide both sufficient vibration mitigation and energy harvesting. This paper presents a prototype of a back-iron-based design of an electromagnetic regenerative tuned mass damper. The mathematical model of the tuned mass damper system was developed and has been validated by the experimental results of the tuned mass damper prototype implemented in a protected mass test-bench. The indicated results concluded that the attenuation performance dramatically deteriorated under random excitations and a reduction in the root-mean-square acceleration of 18% is concluded compared to the case with undamped tuned mass damper. Under harmonic excitations, the designed tuned mass damper prototype is able to reduce the peak acceleration value of the protected structure by 79%. According to the experimental results, the designed tuned mass damper prototype revealed a peak regenerative power of 0.76 W under a harmonic excitation of 8.1 Hz frequency [Formula: see text]m amplitude. Given the simulated random road profiles from C to E, the back-iron electromagnetic tuned mass damper indicated that root-mean-square harvested power from 0.6 to 6.4 W, respectively.

A Model-Based Computationally Efficient Method for On-Line Detection of Chatter in Milling

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
Lei Ma ◽  
Shreyes N. Melkote ◽  
James B. Castle
Keyword(s):  
Cutting Force ◽  
Efficient Method ◽  
Frequency Estimation ◽  
Chip Thickness ◽  
Computationally Efficient ◽  
Model Based ◽  
Chatter Suppression ◽  
Force Signal ◽  
Regeneration Effect ◽  
Milling Chatter

This paper presents a model-based computationally efficient method for detecting milling chatter in its incipient stages and for chatter frequency estimation by monitoring the cutting force signals. Based on a complex exponentials model for the dynamic chip thickness, the chip regeneration effect is amplified and isolated from the cutting force signal for early chatter detection. The proposed method is independent of the cutting conditions. With the aid of a one tap adaptive filter, the method is shown to be capable of distinguishing between chatter and the dynamic transients in the cutting forces arising from sudden changes in workpiece geometry and tool entry/exit. To facilitate chatter suppression once the onset of chatter is detected, a time domain algorithm is proposed so that the dominant chatter frequency can be accurately determined without using computationally expensive frequency domain transforms such as the Fourier transform. The proposed method is experimentally validated.

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