Abstract
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.
Highlights
Industrial robot is a promising technology which has been implemented in the grinding, wielding, and spray-painting processes in industry
For the chatter vibration caused by the low stiffness of the milling robot, it is still a tough problem that needs to be solved
The proposed eddy current dampers (ECDs) are installed on the milling spindle to damp the tool tip vibrations
Summary
Industrial robot is a promising technology which has been implemented in the grinding, wielding, and spray-painting processes in industry. Zaghbani et al.[13] proposed a spindle speed selection method for robotic milling to achieve better vibration suppression performance. The methods proposed in previous works[2,12,13,14] avoid chatter by properly selecting the feed direction, spindle speed, and robot postures. These methods require large amounts of experiments or calculations prior to each machining process, and they are time consuming. ECDs are passive dampers and do not require complex control laws, and they are easy to be implemented These advantages make ECDs a good choice for vibration attenuation in the robotic milling process. The cross-section of the designed ECD which is installed facing the z-direction (Figure 1) is shown in
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