Tunable vibration absorber for improving milling stability with tool wear and process damping effects

This paper deals with the problem of chatter suppression in milling process in order to achieve higher precision, better surface quality and larger material removal rate (MRR). The peripheral milling process is modeled as a two degrees of freedom system and the effects of tool wear and process damping are considered. It is shown that when regenerative chatter develops, both tool wear and process damping act as stabilizing factors. For larger values of depth of cut and consequently higher MRR, tunable vibration absorbers (TVA) (in x–y directions) are designed to improve stability. An optimal algorithm is developed which determines the optimum values for absorbersʹ parameters. The effects of tool wear, process damping and absorbers on the frequency response of the system and on the stability lobe diagram of the process are investigated. It is shown that the deigned absorber set is robust against parametric uncertainties associated with the dynamic model.