TEQIP Workshop on

Machining Dynamics
Machining Process Modelling + Machine Tool Dynamic Testing + Avoidance of Chatter Vibrations
18-22 July 2016

Machine tool/cutting tool design to mitigate vibrations

Dr. Mohit Law

mlaw@iitk.ac.in

IIT Kanpur
 Machine tool dynamic response

FRF   
Displacement
Force

𝑎𝑙𝑖𝑚 ≅ 2k𝜁

1
2k 𝑖 𝜁𝑖 Dynamic
stiffness

1
Static 𝑘
stiffness

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 Chatter mitigation strategies
Machine tool/cutting tool builder viewpoint
Depth of cut
Machine tool user viewpoint

Spindle speed

𝑎𝑙𝑖𝑚 ≅ 2k𝜁
Magnitude X/F [m/N]

Freq. [Hz]
Material removal rate = f (depth of cut, width of cut, feed)
Increase 2k𝜁 Increase MRR

3 IIT Kanpur
 Structure

• Designing machines for productivity

– Topology optimization
– New structural materials
– Design for symmetry
– New machine tool concepts
– Active damping devices
• Designing cutting tools for productivity
– Variable pitch and helix
– Serrated cutters
– Tool tuning – adjust length
– Tool holder
– Passive damping – boring bars
– Process damping – tool geometry

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Topology optimization

1
Original 2k 𝑂𝑟 𝜁𝑂𝑟

1
2k 𝑂𝑝 𝜁𝑂𝑝

Stiffened

𝑎𝑙𝑖𝑚 ≅ 2k𝜁

Optimized 40% increase in productivity

IIT Kanpur
 Topology optimization

Source: ITRI, Taiwan

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 New structural materials

Carbon fiber reinforced plastic (CFRP) Polymer concrete

Rib
thickness
40 mm

Source: Fraunhofer IWU

Slide mass -52%

Stiffness x +14%
Stiffness y +96%
Stiffness z -19%
Source: TU Chemnitz, Germany

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 Design for symmetry

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 Hybrid serial-parallel kinematic machine tool

44.63 Hz, 0.2261%

Z
X Y

Source: Fraunhofer IWU

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 Structure integrated active damping devices

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 Structure

• Designing machines for productivity

– Topology optimization
– New structural materials
– Design for symmetry
– New machine tool concepts
– Active damping devices
• Designing cutting tools for productivity
– Variable pitch and helix
– Serrated cutters
– Tool tuning – adjust length
– Tool holder
– Passive damping – boring bars
– Process damping – tool geometry

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 Variable pitch

Source: Altintas

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 Variable helix

Source: Altintas

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 Variable pitch and helix

Source: Altintas

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 Serrated cutters

Source: Altintas

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 Tool length tuning

Increase/decrease
overhang as per
application

Source: Schmitz

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 Tool holder

𝑎𝑙𝑖𝑚 ≅ 2k𝜁 Power Chuck

Increasing stability
Collet

Hydraulic
1
Dynamic 2k 𝑖 𝜁𝑖 Shrinkfit
stiffness

Source: Altintas

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 Tuned boring bars – passive damping

Source: Sandvik

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 Process damping – reduce tool clearance angle

Source: Enynian, U West

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 Thank you

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