Abstract
Long cantilevered high performance milling tools tend to vibrate during machining operation due to process excitation. This impairs the quality of the workpiece surface and limits the achievable material removal rate. An optimisation of the dynamic properties of these tools enables an increased machining performance. This paper introduces a lightweight design of a shell end milling tool with an integrated semi-active damping system based on magnetorheological fluids. The investigations show that this approach allows an adjustment of the dynamic behaviour of the tool. In machining experiments a significant increase of the material removal rates and improved surface quality are achieved.
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