Additive Manufacturing Damper Nodes for Machining Vibration Control
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Solution Overview
Problem
Existing machining dampers are limited in their ability to effectively dampen a broad spectrum of frequencies, are costly to manufacture, and difficult to adapt for design changes in workpieces, leading to issues like chattering during machining processes which result in poor surface finishes and profile errors.
Innovation Solution
A damper with a body featuring a frame, damper nodes with cavities filled with damping material, and ribs connecting the frame to the nodes, manufactured using additive manufacturing or 3D printing, allowing for easy installation, adaptation, and effective vibration damping across a wide range of frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible damping sheet is used to support the workpiece, then damping effectiveness is improved, but the frequency range is limited to a narrow spectrum
Solution Approach 1:
The damper is divided into multiple discrete nodes distributed across the workpiece surface, with each node containing damping material in a cavity. This segmentation allows the damper to effectively handle multiple vibration modes and frequencies simultaneously, overcoming the narrow frequency range limitation of flexible damping sheets.
2Reliability
If elastomeric dampers are used to attach to the workpiece, then damping is provided, but effectiveness decreases as they age and varies with temperature changes
Solution Approach 1:
The patent replaces elastomeric materials with viscous damping material contained in rigid cavities. This substitution eliminates the aging and temperature sensitivity issues associated with elastomeric dampers, as the viscous damping material's performance is not degraded by time or temperature variations in the same way.
3Reliability
If complex fixtures are fabricated to support and hold workpieces, then damping and support are provided, but manufacturing cost and adaptation cost increase
Solution Approach 1:
The damper design with multiple nodes and cavities can be universally applied to various workpiece geometries and machining scenarios. The same basic damper structure can accommodate different workpiece sizes and shapes by adjusting the number and position of nodes, eliminating the need for custom fixtures for each application and reducing both manufacturing and adaptation costs.
4Adaptability or versatility
If complex fixtures are fabricated to accommodate design changes in workpieces, then support is provided, but adaptation time and cost increase
Solution Approach 1:
The damper design allows for dynamic reconfiguration to accommodate design changes. The nodes and cavities can be repositioned or reconfigured based on the new workpiece geometry, enabling rapid adaptation without requiring complete fixture redesign and manufacturing, thus reducing adaptation time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The damper effectively dampens vibrations across a wide range of frequencies, improving surface finish and profile control, reducing production costs, and enabling faster machining with ease of use and adaptability to different workpiece designs.
Implementation Method 1
Vibrations in the workpiece are dampened with a damping material in the damper nodes of the damper
Data Source
Figure 1A~1B
Figure 2A~3B
Figure 4A~4B
AI summary
A damper (20) includes a damper body (22) that is configured to be attached to a workpiece (10) during a machining process. A first side (26) of the damper body (22) is configured to abut a first side (16) of the workpiece (10). The damper body (22) includes a frame (30) forming an outer periphery of the damper body (22), a plurality of damper nodes (42) with a cavity (48) in each damper node (42) positioned in the frame (30), and a plurality of ribs (44) extending between the frame (30) and the damper nodes (42). A damping material (50) is positioned in the cavity (48) of each damper node (42).