Tunable Mass Element Milling Cutter for Chatter Vibration Control
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Solution Overview
Problem
Existing milling technologies face challenges with stability problems and vibration issues, particularly in elongate milling cutter bodies, leading to irregular surface finishes and chatter vibrations, which are not adequately addressed by prior solutions.
Innovation Solution
The introduction of a milling cutter body with an axial recess containing a tunable mass element, adjustable via tuning members and lockable in position, allows for optimization of natural frequencies by adjusting the mass distribution, thereby enhancing spindle speed and cutting depth combinations to prevent stability problems and chatter vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the protrusion length of the milling cutter body is increased, then the productivity is improved, but the stability deteriorates due to chatter vibrations
Solution Approach 1:
The patent applies dynamics by making the mass element axially movable within the recess instead of fixed. This allows the mass distribution to be dynamically adjusted to shift natural frequencies away from chatter frequencies, stabilizing the system while maintaining the required protrusion length for productivity
Solution Approach 2:
The patent changes the parameter of mass distribution by positioning a mass element within an axial recess. By adjusting the axial position of this mass element, the natural frequencies of the milling cutter body are modified to avoid resonance with chatter vibrations, thereby improving stability without reducing productivity
2Productivity
If the axial cutting depth is increased beyond the critical value, then the productivity is improved, but the stability deteriorates due to excessive vibrations
Solution Approach 1:
The movable mass element enables dynamic tuning of the system's natural frequencies. This allows the system to maintain stability at higher axial cutting depths by adjusting the mass position to shift natural frequencies away from the chatter frequency range, thereby increasing the critical axial cutting depth
Solution Approach 2:
By changing the axial position parameter of the mass element, the natural frequencies of the milling cutter body are adjusted. This parameter change allows the system to operate stably at higher axial cutting depths that would otherwise cause excessive vibrations
3Stability of the object's composition
If the spindle speed is changed to avoid stability problems, then the vibration stability is improved, but the productivity may deteriorate due to speed control limitations and temperature increase
Solution Approach 1:
The patent changes the physical parameter of mass distribution to shift natural frequencies, providing an alternative method to achieve stability without changing spindle speed. This allows maintaining optimal spindle speed for productivity while achieving vibration stability through mass element positioning
Solution Approach 2:
The patent replaces the mechanical control approach of changing spindle speed to avoid vibrations with a structural modification approach using a movable mass element. This substitution allows maintaining constant spindle speed while achieving vibration control through natural frequency adjustment
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
This approach effectively increases the critical axial cutting depth without changing spindle speed, achieving more efficient and stable milling operations by displacing stability lobes and optimizing natural frequencies, resulting in improved surface finishes and reduced vibration issues.
Implementation Method 1
an axial hole in which a damper mass is arranged. The damper mass is suspended by means of elastic O-rings, and the tuning of the damping system is provided by altering the pressure on the O-rings
Implementation Method 2
The damper mass is suspended by means of elastic O-rings
Implementation Method 3
a damping system to damp vibrations that are generated during, for example, milling
Data Source
AI summary
Device and method for milling of materials including a milling cutter body including a first end portion and an opposite second end portion. The first end portion is connected to a rotatable spindle and the second end portion is provided with at least one cutting edge. The milling cutter body defines a longitudinal axis and is provided with an axial recess, wherein at least one mass element is arranged in the recess. The axial position of the mass element in relation to the milling cutter body is tuned by use of tuning members included in the device for the tuning of the natural frequency of the device. The mass element is axially locked in relation to the milling cutter body by use of lock members included in the device, in order to optimize the natural frequency of the device for the milling operation in question.