Design and Analysis of a Mechanical Damper in a Milling Cutter

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Addis Ababa University


When an endmill is used in high-speed machining, chatter vibration of the tool can cause undesirable results. This vibration increases tool wear and leaves chatter marks on the cutting surface. To reduce the chatter vibration, a layered-beam damper is inserted into the hole at the center of the tool. The friction work done by the relative motion between the tool and damper reduces chatter vibration. The purpose of this research is to design and optimize the configuration of the damper to obtain the maximum damping effect. The analytical method has been reviewed, which is based on the assumption of constant contact pressure and uniform deflection. For the numerical approach, nonlinear finite element analysis is employed to calculate the distribution of the contact pressure under the centrifugal and cutting forces. The analytical and numerical results are compared and discussed. In order to identify the effect of the damper’s configuration, two design variables are chosen: the inner radius of the damper and the number of slotted dampers. During the parameter study and optimization, the inner radius is varied from 1.5mm to 3.5mm and the number of slotted dampers is varied from 2 to 10. Results show that the damping effect is maximum when the inner radius is 1.5mm and the number of slotted dampers is 5. However, this result depends on the operating condition. Thus, it is suggested to prepare a set of dampers and to apply the appropriate one for the optimum damping effect for a given operating condition.



Mechanical Engineering