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A piezoelectric vibration sensing system (PVSS) was devised in this study and employed for the purpose of vibration sensing in machining. The system comprises three primary components, wherein the sensor is utilized for the collection and conversion of energy, subsequently transmitting it to the data acquisition card (DAC) via a low-noise cable. The crux of the entire system lies in the upper computer-based control application, which facilitates the transmission of instructions to the DAC for data acquisition and transmission. The integration of Wi-Fi data transfer capability between the DAC and the computer serves to eliminate the principal issue associated with employing the sensor as a voltage source. The sensitivity of the designed device was calibrated utilizing commercial accelerometers, while an aluminum workpiece was fabricated to conduct vibration and machining tests in order to verify the performance of the PVSS. The shaker excitation experiment yielded a peak voltage of 0.05 mV, thereby substantiating that the PVSS can more accurately discern the natural frequency of the workpiece below 5000 Hz compared to commercial accelerometers. The experiments verify that the devised PVSS can precisely measure vibrations during the milling process, and can be implemented for the purpose of detecting machining stability. [ABSTRACT FROM AUTHOR]

Turning cutting tool with large length–diameter ratio has been essential when machining structural part with deep cavity and in-depth hole features. However, chatter vibration is apt to occur with the increase of tool overhang. A slender turning cutting tool with a length–diameter ratio of 7 is developed by using a vibration absorber equipped with piezoelectric ceramic. The vibration absorber has dual functions of vibration transfer to the absorber mass and vibration conversion to the electrical energy via the piezoelectric effect. Equations of motion are established considering the dual damping from the piezoelectric ceramic and rubber gasket. The equivalent damping of piezoelectric ceramic is derived, and the geometries are optimized to achieve optimal vibration suppression. The modal analysis demonstrates that the cutting tool with the vibration absorber can reach 80.1% magnitude reduction. Machining tests are carried out in the end. The machining acceleration and machined surface roughness validate the vibration suppression of the VA, and the output voltage by the piezoelectric ceramic demonstrates the ability of vibration sensing. [ABSTRACT FROM AUTHOR]

The tuned mass damper (TMD) has been used in machining processes for reducing forced vibration, suppressing chatter, and improving machined surface quality. In micro-milling process, the tiny size of the cutting tool-tip and the high rotating speed bring challenges in implementing the TMD. Besides, the TMD needs to have two degrees-of-freedom (DOFs) for reducing vibrations of micro-mill in two orthogonal directions. This paper presents the chatter suppression for micro-milling by attaching a two-DOF TMD to the tool shank and rotates with the cutting tool. The frequency response function (FRF) at the tip of the micro-mill clamped by an aerostatic spindle is predicted using receptance coupling analysis. A two-DOF TMD is designed via graphical approach based on the FRF result at the tool-tip. The natural frequencies and damping ratio of the TMD are optimized under different spindle speeds in order to enhance the cutting stability. The chatter stability of micro-milling is predicted considering the gyroscopic and centrifugal effects of the TMD structure. Modal tests and micro-milling experiments are conducted to validate the effect of the TMD on chatter stability. The results show that the TMD is able to improve the critical depth of cut by 13 folds, and satisfy the compact design requirement for micro-milling. • Shank-mounted TMD satisfies the specific geometric requirement in micro-milling. • Design of TMD using graphical approach based on synthesized FRFs of substructures. • The centrifugal and gyroscopic effects of TMD on chatter stability are studied. • Chatter-free axial depth of micro-milling operation is enhanced by 13 folds. [ABSTRACT FROM AUTHOR]

The optimal parameters of a passive damper (i.e., frequency ratio and damping ratio) for the machining vibration attenuation of thin-walled part are quite affected by the material removal process, and the damper becomes ineffective easily due to its narrow vibration band. A design of passive damper with tunable stiffness is proposed for being adaptive to the varying machining process, and the frequency tuning is carried out by orienting the mass block inside the damper. Modal tests are performed to verify the amplitude reduction of the target mode of the thin-walled part. It shows that the optimal vibration suppression is reached when the orientation is 20° due to a smaller frequency difference between the damper and target mode, and the amplitude of the damped frequency response function is reduced to 1.3 %. Finally, machining tests are carried out, and the machining vibration and surface quality validate the large increase of machining stability. The experimental critical depth of cut under optimal tuning is increased by 1.8-folds compared with the most ineffective tuning, and the machined surface roughness is reduced by more than 80 %. [ABSTRACT FROM AUTHOR]

Thin-walled workpieces are largely manufactured in the aerospace industry. The manufacturing process has been a problem due to its flexibility, and chatter vibrations are apt to occur, which restricts the machining efficiency and quality. A vibration suppression device for thin-walled workpieces is presented based on the electromagnetic induction principle, which utilizes machining vibrations to generate resistant force on the workpiece. The formulated force varies with the workpiece vibration velocity, but in an opposite direction. Excitation tests using the electromagnetic shaker illustrate that the device is effective in vibration attenuation. Finally, machining tests are carried out with applications to two thin-walled structures for further verification. The machining vibrations and surface quality demonstrate the damping promotion of the workpiece assembly, and milling stability limit is increased by more than twofold. [ABSTRACT FROM AUTHOR]

Stability lobes are widely used to avoid chatter which restricts the machining quality and productivity. A lot of work has been done to predict the stability lobes fast and accurately. However, most of them are based on the linear force model, and the chatter stability limit is formulated as independent on the feed rate, which is inconsistent with the machining practice. By referencing with the zero-order solution, this paper investigates the chatter stability prediction based on the exponential force model. Focusing on the cutters with a lead angle (i.e., inserted face mill, the ball-end mill, and bull-nose end mill) where chatter is likely to be brought up in Z direction, the stability model is extended to three-dimensional. Taylor equation is utilized to linearize the exponential expressions when computing the directional coefficients in order to solve the stability limit analytically as the linear force model. Simulation results show that the exponential force model agrees with the measurements as well as the linear force model in the cutting force prediction, and it is able to demonstrate the feed rate effect on the stability limit. The stability limit is found to be increased as the feed rate increases, which is evidenced by the time domain simulation. Cutting tests are performed in the end to verify the stability model. The proposed model could be reduced to either X/ Y dimensional or linear force model-based stability model by further simplifications. [ABSTRACT FROM AUTHOR]

Abstract: A new-type nonlinear tuned mass damper (TMD) containing an additional element of elastic support dry friction compared with the common linear TMD is proposed to suppress machining chatter. The design and tuning process of this nonlinear TMD have used a combination of analytical modeling with experimentally measured frequency response function (FRF) of the machining system. Theoretical studies and experimental results show that the proposed nonlinear TMD can remarkably improve the machining stability by effectively suppressing the magnitude of the real part of the FRF of the damped machining system. [Copyright &y& Elsevier]

• Novel oppositely oriented series MTMDs with compact structure and minimized parasitic vibration. • Formulation of parasitic and primary vibrations for quantitative geometry design of MTMDs. • Practical routine for parameter design and evaluation of MTMDs considering background modes. • Vibration suppression of a parallel machine tool with closely spaced and position-dependent modes. Passive vibration control of the parallel machine tool is challenging due to its closely spaced vibration modes and position-dependent dynamics. Owing to the advantages of significant vibration suppression, high robustness, and no need for additional damping materials, the series multiple tuned mass dampers (MTMDs) appear to be an effective solution to this problem but suffer from large-sized structure and significant parasitic vibrations. This paper proposes a novel type of oppositely oriented series MTMDs with a compact structure and minimized parasitic vibrations, with the effectiveness and robustness of the traditional type retained. An analytical model of the parasitic and primary vibrations of the series MTMDs is presented for quantitative geometry design. The dynamics of the actual main structure and the analytical MTMDs are integrated, followed by the parameter optimization and performance evaluation of the MTMDs considering the effect of background vibration modes. The oppositely oriented series dual-mass TMDs are implemented to suppress the machining vibrations of a parallel machine tool. Modal tests indicate that 72.7% amplitude of the target mode is reduced by the series dual-mass TMDs, which shows a 10.8% improvement compared to the SDOF TMD with equal damper mass. A maximum of 70.1% vibration reduction is achieved in slot milling experiments. [ABSTRACT FROM AUTHOR]