Abstract
Chatter is more likely to occur during the turning process of a thin-walled cylindrical workpiece owing to the low rigidity of such workpieces. Chatter causes intensive vibration, deterioration of the surface finish accuracy, tool damage, and tool wear. Tuned mass dampers (TMD) are usually applied as a passive damping technique to induce a large damping effect using a small mass. This study experimentally investigated the effect of the mounting arrangement and tuning parameters of the TMDs on the production of chatter during the turning process of a thin-walled cylinder, wherein multiple TMDs with extremely small mass ratios were attached to the rotating workpiece. The results of the cutting tests performed by varying the circumferential and axial mounting positions of the TMDs exhibited different characteristics of the chatter suppression effect. Conclusively, the TMDs could suppress the chatter generated by the vibration mode with circumferential nodes if they were mounted on the workpiece to avoid the coincidence of the circumferential arrangement with the pitch of the vibration nodes, regardless of the extremely small mass of the TMDs.
Highlights
Thin-walled, lightweight parts are adopted in the aerospace and automobile industries to further improve fuel efficiency
This study proposed a method for effectively suppressing the chatter during the turning process of thin-walled cylinders using lightweight Tuned mass dampers (TMD)
The major conclusions are summarised as follows: (1) The chatter can be controlled if the masses or TMDs are attached to the workpiece such that their mounting arrangements do not coincide with the spacing of the nodes of the generated chatter vibration mode
Summary
Thin-walled, lightweight parts are adopted in the aerospace and automobile industries to further improve fuel efficiency. Vibrations can occur during the cutting process owing to the low rigidity of the thin-walled and lightweight parts. Extensive research has been conducted to improve the machining of the thin-walled parts [1,2,3,4,5]. Machine tool operators use various trial-and-error measures such as applying fixtures to the workpiece to increase its rigidity [8,9,10,11,12] and reducing the cutting speed and depth of cut. The reduction in cutting speed and depth of cut decreases the machining efficiency. The application of the workpiece fixture requires time, money, and empirical knowledge because the workpiece fixtures must be elaborately manufactured according to the workpiece dimensions and shapes
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