Design and Analysis of a Mechanical Damper in a Milling Cutter
No Thumbnail Available
Date
2009-07
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Addis Ababa University
Abstract
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.
Description
Keywords
Mechanical Engineering