Optimization of Tuned Mass Damper Location for Enhanced Chatter Suppression in Thin-wall Milling

Abstract

In this paper, a method to optimize the location of tuned mass damper (TMD) for enhancing chatter stability limits of thin-walled workpiece by using numerical techniques is proposed with due consideration to mass effect of TMD. The dominant mode of workpiece is identified from the simulated and measured frequency response functions of the workpiece. Two TMDs each having single degree of freedom are designed and a finite element model to predict the response of the workpiece-damper system is developed. The effect of damper location on the chatter stability of the thin-walled workpiece is investigated. Further, the locations for TMDs are optimized for enhanced chatter stability of workpiece by using response surface methodology. Milling tests were performed on workpiece with and without TMDs. A three-fold improvement in minimum stable depth of cut is realized after incorporating the TMDs at their optimal locations on thin-walled workpiece.