Design of an Additional Absorber for Turning Tool

Pai-Chung Tseng
Chung-Ju Chang

50%~160%

ii

Abstract
Chatter often occurs when the depth of cut is increased. Chatter not only damages
the accuracy of the workpiece surface and geometric, but also destroys the tool, spindle,
bearings and other key components. It must be prevented or avoided. For these
problems, this study designs an additional absorber to increase the dynamic
characteristics of turning tool.
First, this study investigates the causes of chatter and compares the advantages

of

various absorbers from documents. Then from the equation of motion, the important
parameters are known. The finite element method is used to analysis the additional
absorber. Finally, some experiments are made to compare the surface quality when
machining with and without the absorber.
Experimental results show that the additional absorber can increase the limits depth
of cut ranging from 50% to 160%, and improve surface accuracy.

Keyword: Chatter, Absorber, Turning

iii

................................................................................................................................... i
.................................................................................................................................. ii
Abstract............................................................................................................................ iii
................................................................................................................................. iv
............................................................................................................................. vi
............................................................................................................................. ix
.................................................................................................................... 1
1.1 ............................................................................................... 1
1.2 ........................................................................................................... 2
1.3 ........................................................................................................... 5
.................................................................................... 6
2.1 .................................................................................................... 6
2.1.1 ................................................................................................. 6
2.1.2 ................................................................................................. 7
2.1.3 ................................................................................................. 8
2.2 ..................................................................................................... 10
2.3 ..................................................................................................... 12
2.3.1 ...................................................................................... 13
2.3.2 ................................................................................... 13
2.3.3 ...................................................................................... 15
2.3.3.1 ............................................................................... 15
2.3.3.2 ............................................................................... 15
iv

2.3.3.3 ........................................................................ 16
2.3.3.4 ............................................................................... 17
2.3.3.5 ............................................................................... 18
2.3.3.6 ........................................................................... 19
.......................................................................................... 20
3.1 .............................................................................................. 20
3.2 ................................................................................. 21
3.3 ................................................................................................. 25
...................................................................................... 36
4.1 ......................................................................................................... 36
4.1.1 .............................................................................................. 36
4.1.2 ........................................................................................... 37
4.1.3 ....................................................................................................... 38
4.1.4 .............................................................................................. 39
4.2 .......................................................................................................... 39
4.2.1 ............................................................................................... 40
4.2.2 ........................................................................... 41
4.3 ............................................................................................. 44
4.3.1 ...................................................................................... 44
4.3.2 ...................................................................................... 44
4.3.3 .......................................................................... 46
.............................................................................................. 49
5.1 ................................................................................................................. 49
5.2 ......................................................................................................... 49
........................................................................................................................ 51
v

1.1 (a)(b) ............................................. 2

1.2 (a)(b) ..................................... 3
2.1 .................................................................................................. 7
2.2 ...................................................................... 8
2.3 .................................................................................................. 9
2.4 ...................................................................................... 9
2.5 ................................................................................................ 10
2.6 .................................................................................................11
2.7 .................................................................................................... 12
2.8 ........................................................................................ 13
2.9 ............................................................................................ 14
2.10 MR ........................................................................................ 14
2.11 .............................................................................................. 15
2.12 .......................................................................................... 16
2.13 .......................................................................................... 17
2.14 ...................................................................... 17
2.15 .......................................................................... 18
2.16 ...................................................................................................... 18
2.17 .................................................................................................. 19
3.1 ........................................................................ 20
3.2 ........................................................ 24
3.3 ................................................ 24
vi

 3.4 ........................................................ 25
3.5 ........................................................................................................ 26
3.6 .................................................................................... 27
3.7 .................................................................................................... 27
3.8 ............................................................................................................ 29
3.9 ........................................................................................................ 29
3.12 X ............................................................................................... 31
3.13 Y ............................................................................................... 31
3.14 Z ................................................................................................ 32
3.15 X ....................................................................................... 33
3.16 X ............................................................................................... 33
3.17 Y ............................................................................................... 34
3.18 Z ................................................................................................ 34
4.1 GCL-2L CNC ................................................................... 37
4.2 Kosaka SE3500K ........................................................ 38
4.3 ............................................................................................................ 38
4.4 ........................................................................................ 39
4.5 .................................................................................... 40
4.6 ........................................................................................ 42
4.7 ............................................................................................ 42
4.8 ................................................................................................ 43
4.9 ................................................................................................ 43
4.10 .......................................................................... 46
4.11 .............................................................................. 46
4.12 .................................................................................................. 47
vii

 4.13 ...................................................................................... 48

viii

3.1 ........................................................................................................ 28
4.1 ................................................................................................ 36
4.2 Kosaka SE3500K ....................................................................... 37
4.3 ............................................................................................ 39
4.4 S45C ................................................................................... 41
4.5 S45C ............................................................................................... 41
4.6 ............................................................................................................ 41
4.7 ................................................................................................ 44
4.8 20mm .................................................................... 45
4.9 25mm .................................................................... 45
4.10 30mm .................................................................. 45

ix

1.1

chatter

(free vibration)(Forced vibration)

(Self-excited vibration)

1.2

19

Y.Altintas M.Weck[1]

[2]

1.1 (a)(b)[2]
2

1.2 (a)(b)[2]

[3]

Achala V.Dassanayake C.Steve Suh[4]

Emre Ozlu Erhan Budak[5]

[6]--

[7]

[8] MEscope

K.Li A.P.Darby[9]

Y.S.Tarng [10]

6
Min Wang [11](TMD)

Etsuo Marui [12]

Etsuo Marui

[13](adaptive filter)

(feedback FXLMS)

FXLMS

[14]

 0.66% 4.02%

1.3

2.1

2.1.1

mx + cx + kx = 0
2.1

 2.1 [14]

2.1.2

3
(built-up edge)


2.1.3

2.2

2.2 [15]

1(regenerative chatter)

2.3

 2.3 [14]

2(mode coupling chatter)

2.4
X2 X1

A B
B A

2.4 [15]
9

2.2

Merritt[1]

Merritt 2.5

2.5 [16]
10

 h0 (s) h(s) y(s)

f c (s) f f1 f1 f

2.6 Merritt Gm (s)
y(s) kc (cutting coefficient)b

1
N (overlap factor)
N

2.6 [16]

(stability lobes) 2.7

11

 2.7 [16]

2.7

blim =

1
2kc G ()

(2-1)

G ()

2.3

12

2.3.1

2.8 [17]

2.3.2

13

2.9

2.9 [18]

2.10 MR [19]

14

2.3.3

2.3.3.1

Chih-Cherng Chen
Ko-Ta Chiang[20]

2.11 [20]

2.3.3.2

15

 K. Li
A.P. Darby[9]

2.12 [21]

2.3.3.3

[14]

16

 2.13 [14]
2.3.3.4

Min Wang [11](TMD)

Etsuo Marui [12]

2.14 [11]

17

 2.15 [12]

2.3.3.5

Kuanmin
Mao [22]

2.16 [22]
18

2.3.3.6
Jae-Sung Bae [23]

2.17 [23]

19

ANSYS
A

3.1

3.1

k1 m1

x1 x1 x1

c k2 m2

x2 x2 x2

3.1

3.1

20

T=

1
1
m1 x12 + m2 x22
2
2

(3-1)

3.1
U=

1 2 1
2
k1 x1 + k2 ( x1 - x2 )
2
2

(3-2)

F1 = -c ( x1 - x2 ) + F ( t )

(3-3)

F2 = -c ( x2 - x1 )

(3-4)

F (t ) (3-1)(3-4) Lagrange equation

T T U
+
= F1

t x1 x1 x1

(3-5)

T T U
+
= F2

t x2 x2 x2

(3-6)

m1
x1 + k1 x1 + k 2 ( x1 x2 ) + c ( x1 x2 ) = F ( t )

(3-7)

m2
x2 + k2 ( x2 x1 ) + c( x2 x1 ) = 0

(3-8)

(3-7)(3-8)

3.2

F (t )
F (t ) = F0 eit

(3-9)

F0 F (t ) F (t )

21

x1 = x1eit

(3-10)

x2 = x2 eit

(3-11)

x1 x2 x1 x2 (3-9)(3-10)(3-11)(3-7)(3-8)

( m1 2 + k1 + k2 + ic ) x1 ( k2 + ic) x2 = F0

(3-12)

( k 2 + ic ) x1 + ( m2 2 + k 2 + ic ) x2 = 0

(3-13)

(3-12)(3-13) x1

x1 =

F0 ( k2 m22 ) + ic

(3-14)

A1

A1 = ( m1 2 + k1 )( m2 2 + k 2 ) m2 2 k 2 + ic m1 2 + k1 m2 2

(3-15)

(Dynamic Magnification Factor) x1

x
DMF = 1 =
xst

(k

m2 2 ) + ( c )
2

A2

A2 + B 2
C 2 + D2
2

k m

m 2 k2
m1 2 m2 2
2 k1
A2 = 1 1 2 ( k2 m2 2 ) 2

+ ( c )
k1
k1

k1 k1

k1 k1

(3-16)
2

(3-17)

xst = F0 / k1
A=

k2 / m2
2

= f 2 g2
k1 / m1 k1 / m1

B=

k2 / m2
m1c
c
= 2

2 m k k / m
m2 k1
2 2
1
1

(3-18)

k / m
1 1

22

= 2fg

(3-19)


2 k2 / m2
2 m2 k2 / m2 2

C = 1

k1 / m1 k1 / m1 k1 / m1 m1 k1 / m1 k1 / m1

= (1 g 2 )( f 2 g 2 ) f 2 g 2

(3-20)

m c k m

m
D = 1 1 2 2 1 2 = ( 2fg ) (1 g 2 g 2 )
k1
m2 k1 k1 k1

(3-21)

(3-18)(3-21) g f

m2
m1

(3-22)

c
2 m2 k2

(3-23)

g=

k1 / m1

(3-24)

f =

k2 / m2

(3-25)

k1 / m1

MATLAB

1/51/101/201/40
3.2

23

 3.2

0.80.91.01.1
3.3
0.9 0.8 1.0
(25) k2
k

3.3

24

 0.050.10.20.41.0
3.4
0.2
0.1

3.4

3.3

25

3.5

3.5
3

26

 3.6

3.7

3.6 3.7

27

 1/10 1/5

ANSYS

(Harmonic Response)

SolidWorks ANSYS
3.8 1000N

3.1
(kg/m)

(GPa)

7850

200

0.3

7890

226

0.29

11400

14

0.42

28

 3.8

3.9

29

 3.10

3.11

30

1.00E-01

9.00E-02

X(mm)

8.00E-02
7.00E-02
6.00E-02
5.00E-02
4.00E-02
3.00E-02
2.00E-02
1.00E-02
0.00E+00
400

2400

4400

6400

8400

10400 12400 14400 16400 18400

(Hz)
3.12 X

1.40E-01

1.20E-01

Y(mm)

1.00E-01
8.00E-02
6.00E-02
4.00E-02
2.00E-02
0.00E+00
400

2400

4400

6400

8400

10400 12400 14400 16400 18400

(Hz)
3.13 Y

31

5.00E-02

4.50E-02

Z(mm)

4.00E-02
3.50E-02
3.00E-02
2.50E-02
2.00E-02
1.50E-02
1.00E-02
5.00E-03
0.00E+00
400

2400

4400

6400

8400

10400 12400 14400 16400 18400

(Hz)
3.14 Z

3.12 3.13 3.14 X 0.091mm

0.078mm 10989N/mm 12821N/mm 17%
Y 0.120mm 0.051mm 8333N/mm
19608N/mm 135%Z 0.044mm
0.028mm 22727N/mm 35714N/mm 57%
ANSYS
X Y

Y X 3.15

32

 3.15 X

1.00E-01

9.00E-02

X(mm)

8.00E-02
7.00E-02
6.00E-02
5.00E-02
4.00E-02
3.00E-02
2.00E-02
1.00E-02
0.00E+00
400

2400

4400

6400

8400

10400 12400 14400 16400 18400

(Hz)
3.16 X

33

1.40E-01

1.20E-01

Y(mm)

1.00E-01
8.00E-02
6.00E-02
4.00E-02
2.00E-02
0.00E+00
400

2400

4400

6400

8400

10400 12400 14400 16400 18400

(Hz)
3.17 Y

5.00E-02

4.50E-02

Z(mm)

4.00E-02
3.50E-02
3.00E-02
2.50E-02
2.00E-02
1.50E-02
1.00E-02
5.00E-03
0.00E+00
400

2400

4400

6400

8400

10400 12400 14400 16400 18400

(Hz)
3.18 Z

3.16 3.17 3.18 X 0.091mm

34

 0.040mm 10989N/mm 25000N/mm 128%

Y 0.120mm 0.130mm 8333N/mm
7692N/mm 8%Z 0.044mm
0.020mm 22727N/mm 50000N/mm 120%

35

4.1

4.1.1
CNC GCL-2L
4.1

4.1

230 mm

300 / 600 mm

8" ()

4500 rpm

125 mm

620 mm

1 ~ 4800 mm / min

8
36

0.005 mm

0.003 mm

FANUC Oi-TD

4.1 GCL-2L CNC

4.1.2
Kosaka SE3500K 4.2
0.001m 4.2

4.2 Kosaka SE3500K

Cut off

0.8 mm

Speed

0.2 mm/s

E. length

Cut off x 5

V. mag

2000
37

H. mag

10

4.2 Kosaka SE3500K

4.1.3
SCLCR2020K-09
CCMT09T304HQ

4.3
38

4.1.4
Kistler
4.3(National
Instruments)USB-6251 60KHz
LabVIEW
MATLAB

4.4

4.3

100mV/g

50g

1.5Hz~6KHz

4.2

39

4.5

4.5

4.2.1
S45C 4.4 4.5
4.6

40

 4.4 S45C

58kgf/mm2

35kgf/m2

20%

45%

167~229HB

4.5 S45C
C

Si

Mn

0.42~0.48

0.15~0.35

0.6~0.9

0.030

0.035

4.6

30 mm

150 mm

120 m/min

0.2 mm/r

25 mm

100 mm

120 m/min

0.2 mm/r

20 mm

100 mm

100 m/min

0.2 mm/r

4.2.2

Kosaka SE3500K

4.6

41

 4.6

RaRzRmax[24][25]
Ra()

n
n
Ra =

y1 + y2 + y3 + ... + yn
n

(4-1)

4.7 [24]

42

Rz()
5 5 ISO
5 5 JIS
3 3

4.8 [25]

Rmax()

4.9 [24]

43

4.3

4.3.1

0.05mm
4.7

4.7

20mm

0.25mm

0.3mm

0.4mm

25mm

0.3mm

0.25mm

0.8mm

30mm

0.3mm

0.3mm

0.45mm

4.7

50% 166%
25mm
20mm 30mm 15 25mm
14
4.3.2
0.35mm
44

4.8 20mm
( m )

Ra

Rz

Rmax

Ra

Rz

Rmax

2.253

8.229

11.531

2.428

8.017

17.056

2.266

8.014

11.841

2.347

7.689

15.465

4.9 25mm
( m )

Ra

Rz

Rmax

Ra

Rz

Rmax

2.299

7.84

11.486

2.528

7.829

20.573

2.273

7.787

10.603

2.251

7.644

11.908

4.10 30mm
( m )

Ra

Rz

Rmax

Ra

Rz

Rmax

2.286

7.711

12.085

3.67

11.203

26.911

2.357

7.809

11.047

2.533

7.776

17.3

B A

45

 4.10 4.11 4.10

4.11

4.10

4.11

4.3.3

4.12
Y
46

4.12

4.13 30mm
150mm 120m/min 0.2mm/r 0.35mm
4.13

47

 4.13

48

5.1

ANSYS

1.
50%~166%
2.

3.

5.2

1.

2.
49

3.

50

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[2] 2006

[3] 2000

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[6] 2008

[7] 2012

[8] 2007
() 28 4
[9] K. Li, A.P. Darby , 2006 , An experimental investigation into the use of a buffered
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51

with a tuned vibration absorber , Journal of Materials Processing Technology 105

(2000) 55-60.
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[13] 2010
18
[14] 2005

[15] 2005

[16] 2009

[17] 2008

[18] Min Wang , Renyuan Fei , 1999 , Improvement of machining stability using a
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Struct. 8 (1999) 511514.
[19] 2009
17 12
[20] Chih-Cherng Chen , Ko-Ta Chiang , 2011 , Analyzing the design of vibration
reduction with the rubber-layered laminates in the precision turning with a diamond
52

cutting tool , Int J Adv Manuf Technol (2011) 57:101116.

[21] Satoshi Ema , Etsuo Marui , 2000 , Suppression of chatter vibration of boring
tools using impact dampers , International Journal of Machine Tools & Manufacture
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[23] Jae-Sung Baea, Moon K. Kwak, Daniel J. Inman , 2005 , Vibration suppression
of a cantilever beam using eddy current damper , Journal of Sound and Vibration 284
(2005) 805824.
[24] 2001

[25]
http://www.goldenhope.com.tw/upload/-1.pdf
[26] Emre Ozlu , Erhan Budak , 2007 , Analytical Modeling of Chatter Stability in
Turning and Boring OperationsPart II: Experimental Verification , Journal of
Manufacturing Science and Engineering, Transactions of the ASME, v 129, n 4, p
733-739.
[27] 2010
23 4 468-474
[28] 2008

[29] 2006
[30] 2005ANSYS
[31] MILTON C.SHAW 1990
53


[32] 2008 SolidWorks 2008

[33] 2012ANSYS Workbench 13.0

54