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Experimental analysis of the influence of a high dampinginterface in a machining system designed for improvingmilling process performance
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0002-5960-2159
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
2010 (English)In: Process machine interactions: conference proceedings, 2010Conference paper, Published paper (Refereed)
Abstract [en]

Role of structural damping in the machining systems is well established andit is known that higher damping in machine tool structures extends the limits ofunconditional process stability regime in the stability lobes diagrams. Despite itssignificant contribution in process improvement the research on damping-basedimprovement in machining performance has been very limited in comparison toadaptive control of dynamic instability through optimum process parameters based onstability lobes’ characteristics of the machine tools. Conventional solutions forimproving damping in machining systems usually target one component at a time, e.g.cutting tools in case of boring bars, machine spindles in case of milling etc. Thisapproach has its limitations as the damping in single components can’t be increased tolevels for a significant contribution at the system level and very often withoutworsening their rigidity. An alternate to this conventional approach is to consider allcomponents of the elastic chain of the machining system- the machine, the cutting toolsand the workholding- for addition of damping, simultaneously. In this way a muchhigher amount of damping can be added into the system without deteriorating structuralrigidity of a single component. This research investigates the potential of high dampingin a milling system added through a workholding system, in this case. A High DampingInterface (HDI), based on a composite of metal-viscoelastic polymer is developed andintegrated in a palletized workholding system and analyzed experimentally. Theexperimental modal analysis and lab-machining tests show more than 50% reduction invibration amplitudes of natural frequency modes of the workpiece held on theworkholding system. The system is further tested in industrial machining environmentshowing up to 17x increase in metal removal rates and 100% improvement in surfacefinish in end milling operations. Ultimate objective of this research is to develop amachining system with its critical joint-interfaces replaced by HDIs with knowncharacteristics. The HDIs should be designed and distributed throughout the system in amanner that they play a dominant role in defining the dynamic behavior of themachining system.

Place, publisher, year, edition, pages
2010.
Keyword [en]
Vibration damping, dynamic stiffness, palletised workholding, highdamping interface, viscoelastic polymer, milling
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-116471ISBN: 978-0-9866331-0-2 (print)OAI: oai:DiVA.org:kth-116471DiVA: diva2:589709
Conference
2nd CIRP Conference on Process Machine Interaction (PMI); Vancouver, BC, Canada, 10-11 June 2010
Funder
XPRES - Initiative for excellence in production research
Note

QC 20130918

Available from: 2013-01-18 Created: 2013-01-18 Last updated: 2013-09-18Bibliographically approved

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Rashid, Amir

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