Abstract
Abstract Chatter is a limiting factor during boring of deep holes with long slender boring bars. In this article, a new magnetorheological (MR) damper is introduced to increase the stability of the boring process. The sponge-type configuration of the damper utilizes a minimal amount of MR fluid in the annulus around the boring bar. The MR fluid layer and the electromagnetic circuit are externally applied to the boring bar, which allows easy installation and adjustability in bar length. A custom made, bidisperse MR fluid is used to eliminate particle sedimentation and enhance the lifetime of the damper. The modal analysis of the boring bar with the new MR damper shows improvements in both the damping and the dynamic stiffness of the system. This enhancement significantly increases the chatter-free depth of cut on the stability lobe diagrams. This article presents the experimental validations on the boring of AL 7075 and Inconel 718 workpieces which are materials widely used in many aerospace applications. The damper is installed on a conventional boring bar for a CNC machining center setup, and its performance is tested under various machining conditions.
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