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Forced vibration mechanism and suppression method for thin-walled

workpiece milling

Xing Yuan , Shuting Wang , Xinyong Mao , Hongqi Liu ,

Zhaoshun Liang , Qiushuang Guo , Rong Yan

PII: S0020-7403(22)00447-7
DOI: https://doi.org/10.1016/j.ijmecsci.2022.107553
Reference: MS 107553

To appear in: International Journal of Mechanical Sciences

Received date: 8 March 2022

Revised date: 1 July 2022
Accepted date: 15 July 2022

Please cite this article as: Xing Yuan , Shuting Wang , Xinyong Mao , Hongqi Liu , Zhaoshun Liang ,
Qiushuang Guo , Rong Yan , Forced vibration mechanism and suppression method for
thin-walled workpiece milling, International Journal of Mechanical Sciences (2022), doi:
https://doi.org/10.1016/j.ijmecsci.2022.107553

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 Highlights:
 The forced vibration mechanism of the thin-walled workpiece under various factors is proposed.
 The response mechanism of the shear thickening fluid under the forced vibration shock is
proposed.
 The parameter relationship between the shear thickening fluid and the thin-walled workpiece
under impact condition is analyzed.
 The vibration of the thin-walled workpiece is effectively suppressed, and the surface quality of
the workpiece to be machined is improved.
Forced vibration mechanism and suppression method for
thin-walled workpiece milling
Forced vibration mechanism and suppression method for
thin-walled workpiece milling

Xing Yuan
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
vaestar@foxmail.com

Shuting Wang*
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
wangst@hust.edu.cn

Xinyong Mao*
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
maoxyhust@hust.edu.cn

Hongqi Liu
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
liuhq@hust.edu.cn

Zhaoshun Liang
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
liangzs@hust.edu.cn

Qiushuang Guo
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
guoqshust@foxmail.com

Rong Yan
School of Mechanical Science and Engineering
Huazhong University of Science and Technology, Wuhan, 430074, China
yanrong@hust.edu.cn

______________________________________
*Corresponding Author: Shuting Wang and Xingyong Mao

Abstract
Thin-walled workpieces are widely used in aerospace applications, but their weak stiffness
characteristic leads to forced vibration during milling, which reduces the quality of the milled surface.
To solve the forced vibration problem in milling thin-walled workpieces, this paper proposes a forced
vibration mechanism for the thin-walled workpiece under the influence of various factors and a
corresponding suppression method. First, the response characteristics of the thin-walled workpiece
excitation features correlated with the mode shape are given. Then, the vibration shapes of the
thin-walled workpiece are combined with the cutting position, and the effects of the cutting force
frequency and cutting force magnitude are also considered. Finally, the different vibration
characteristics are associated with the time constant properties of the shear thickening fluid (STF), and
the corresponding forced vibration effects are suppressed by the STF. After a series of experimental
modal analyses and cutting experiments, the results show that the proposed theory can explain the
forced vibration phenomenon of the thin-walled workpiece, and the vibration suppression effect of the
STF is consistent with the theory. The method is also applicable to vibration suppression at the weak
position during the machining of the large workpiece.
Keywords: Thin-walled workpiece; Machining process; Shear thickening fluid; Mode shape; Natural
frequency.

1 Introduction

Thin-walled workpieces with low weight and high strength are widely used in automobiles [1] and
aviation [2]. However, vibration can lead the workpiece to exhibit low surface quality [3] and poor
dimensional accuracy [4]. The dynamic characteristics of the machine structure [5], including the cutter,
spindle, and machine frame, can lead to vibration phenomena. In particular, regenerative chatter [6]
caused by variations in the cutting thickness and forced vibration [7] caused by high-frequency cutting
force variations are widespread in thin-walled workpiece machining. Therefore, many scholars have
focused their research on vibration recognition and suppression.
In the milling process, researchers usually select machining parameters by drawing a stability lobe
diagram (SLD) to avoid the regenerative chatter problem [8]. Researchers have proposed various
methods for calculating SLDs, considering the workpiece material characteristics [9], variable-speed
spindles [10], process damping [11], force–deformation effects [12], viscous fluids [13], and other
influencing factors. However, the complex machining conditions make it difficult to draw the SLD
accurately, so the machining parameters in the stability area of the SLD still have to be chosen carefully.
Moreover, the chattering phenomenon problem that occurs during the milling process can be overcome
through reasonable machining parameter selection, but the forced vibration issue still exists.
Unlike the general machining process, the weak stiffness [14] of the thin-walled workpiece
determines its low natural frequency; thus, it is more likely to generate forced vibrations [15] during
machining. When forced vibration was first mentioned in machining, scholars mainly focused on the
modal of the cutter and the machine tool [16, 17]. However, less attention was given to the modal
analysis of the workpiece. Actually, in the machining of a thin-walled workpiece, the natural frequency
of the cutter is much larger than that of the workpiece, so a complete understanding of the natural
frequency for the workpiece has theoretical significance for vibration suppression. For the forced
vibration of the thin-walled workpiece, the vibration position and the vibration amplitude of each
position should be determined by modal analysis theory. Gupta et al. [18] proposed a vision-based
cutter motion registration and modal analysis method. Li et al. [19] considered the dynamic
characteristic of the cutter and accurately estimated the dynamic modal parameters of the entire
machine structure. Based on this study, Luo et al. [20] presented a basic mathematical model for
predicting the natural frequency change resulting from a structural change followed by experimental
validation. Berthold et al. [21] determined that the dynamic characteristics of the workspaces for
machine tools were different during the movement process. Pislaru et al. [22] used wavelet transform to
identify the modal parameter of CNC machine tools. Zaghbani et al. [23] describe the complete
methodology of applying the operational modal analysis technique to machining operation in detail and
estimate the dynamic parameters of the machine tool during machining. Wang et al. [24] studied the
influences of modal shape and tool orientation on the evolution of dynamic responses in 5-axis milling
of thin-walled workpieces. Yuan et al. [25] demonstrated the principle of a complex frequency-domain
method for modal identification of ultra-precision fly-cutting machine tools. These works have
successfully applied modal analysis theory to analyse the vibration characteristics of machine tools, but
few studies have used modal analysis theory to analyse the vibration deformation of the workpiece.
Modal shape [26], excitation position [27], excitation force [28], and excitation frequency [29] are
important parameters determining the actual vibration position and amplitude in modal analysis theory.
Corresponding to the process of machining the thin-walled workpiece, the cutting position, the
amplitude of the cutting force, and the cutting frequency all affect the vibration characteristic of the
thin-walled workpiece. Dilena et al. [30] studied the effect of a single crack on the nodal movement of
thin-walled beams in bending vibration, but his research was conducted on a plate. Subsequently, Wang
et al. [31] illustrate the node theory of modal vibration on this basis, which means different vibration
results when the excitation position changes, but this theory is only applied in the vibration analysis of
the complete machine tool. Wang et al. [32] proposed a coupling relationship between modes, but the
idea was only used to study SLDs. In the study of Tang [33], the effects of cutting force and cutting
positions on the machining deformation of the thin-walled workpiece are confirmed, but these analyses
are performed under static conditions and do not consider the forced vibration. Ma et al. [34] developed
a plan for determining the instantaneous cutting amount of thin-walled curved workpieces during
5-axis machining to avoid deformation of the workpiece caused by the change in cutting position. Fu et
al. [35] used a cutting force model to predict chatter in machining, which illustrates the strong
relationship between cutting forces and vibration. Wang et al. [36] considered the influence of cutter
vibration when establishing a cutting force prediction model. Lin et al. [37] obtained the mechanism of
surface ripple formation during milling by comparing the frequency information from wavelet analysis,
the milling vibration signal, and the first-order natural frequency of the system. In his study, the effect
of the cutting frequency on vibration appears to be prominent. Jung et al. [38] analysed the mechanism
of multimode vibration based on the principle of multiple frequency vibrations of the cutter tip.
According to the above scholars, the cutting position, cutting force magnitude, and cutting frequency
directly affect the vibration characteristics of the thin-walled workpiece. However, there is no study to
explain this systematically.
The above three factors determine the complex time-varying vibration characteristics in
machining the thin-walled workpiece; after these characteristics are identified through modal analysis
theory, they need to be suppressed. To overcome the thin-walled workpiece suppression problem,
researchers have used various dampers for vibration suppression [39-43]. Kim et al. [44] used a
mechanical damper to suppress vibration during cutting and calculated the friction power dissipated by
the dampers. Rashid et al. [45] developed and tested tuned viscoelastic dampers for vibration control by
applying them to a workpiece in a milling operation. Kolluru et al. [46] applied dampers on the
workpiece surface to minimize vibration in thin-walled shell milling. Wang et al. [47] proposed a
dynamic model of flexible fixtures for thin-walled casings and analysed the effect of flexible fixtures
on the vibration suppression of thin-walled casings. Hou et al. [48] proposed an approach to enhance
the machining stability of titanium hollow blades by introducing multiple damping and rigid supports
to the blade machining system in the multi-axis milling process. However, the above dampers cannot
fit the dynamic characteristics of the thin-walled workpiece under the influence of material removal.
Therefore, researchers have developed various dampers in which the stiffness can be adjusted to
improve the suppression of time-varying vibration characteristics. Yang et al. [49] designed a damper
with adjustable stiffness to suppress milling vibration. Liu et al. [50] developed a novel constrained
layer damping tool holder to increase the chatter stability of end milling operations. Yuan [51]
proposed a new idea for designing a tunable mass damper (TMD) to reduce vibrations in the milling of
cylindrical parts. Wan et al. [52] presented a new method to suppress chatter vibrations in the milling
process of a weakly rigid workpiece through a moving device. Other researchers have introduced
magnetorheological dampers to suppress vibrations in milling with good results [53-57]. Yang et al. [58]
proposed a lightweight damping device using eddy current damping to suppress vibrations in the
milling process. To increase the damper vibration suppression effect, Butt et al. [59] designed a
two-degree-of-freedom device with damping effects caused by magnetic flux variations and used it to
reduce the milling vibration amplitude. Wan et al. [60] developed a noncontact electromagnetic
actuator with two degrees of freedom and compactly integrated it into the designed spindle system to
suppress milling chatter vibration and improve surface finishes. Saleh et al. [61] developed a new
sponge-type magnetorheological fluid damper for boring bars. In his research, a ring shape around the
boring bar of the dampers was used to provide damping in all radial directions. Based on their studies,
Ma et al. [62] developed a dynamic response prediction model of a thin-walled workpiece-fixture
system with magnetorheological properties, and the feasibility and effectiveness of the proposed
approach were validated by experiments. Although the above dampers showed good suppression of
milling vibration in the experiments, the application range of each damper is limited. In addition, in the
milling process, on the one hand, the vibration in the machining of curved workpieces is spatial, and
the damper can only suppress the vibration in one direction; on the other hand, the damper cannot be
placed in the workpiece cavity to suppress the vibration.
However, dampers cannot solve the complex vibration problems in machining thin-walled
workpieces. Dang et al. [63] proposed a method to mitigate chatter in milling by filling the thin-walled
workpieces with viscous fluid, but the effect of the fluid on forced vibration without chatter was not
discussed. Zhang et al. [64] developed a novel method to mitigate the chatter of a thin-walled
workpiece by submerging the milling system in a viscous fluid. This method can greatly suppress the
chatter of thin-walled workpieces, but the application is more complicated. This paper selects a new
functional material in the industry - shear thickening fluid (STF), which is a mixture of polyethylene
glycol and silica that has been proven to have shock resistance and fast response time and the process is
reversible. Gürgen et al. [65] first applied an STF to machining tools to improve the vibration damping
performance of a turning cutter and achieved good results. However, no literature has been published to
study the vibration suppression of the workpiece in milling with STF.
For the complex forced vibration characteristics of the thin-walled workpiece, the forced vibration
mechanism of the thin-walled workpiece and the corresponding vibration suppression method are
proposed in this paper. First, the cutting position-related vibration characteristic change, the cutting
force frequency-related vibration mode change, and the cutting force-related vibration amplitude
change mechanisms during the milling of the thin-walled workpiece are comprehensively considered.
Then, based on these mechanisms, a vibration suppression method using shear thickening fluid (STF)
is developed. The dynamic model of the STF and thin-walled workpiece under forced vibration is
established, and the vibration characteristics of the thin-walled workpiece are correlated with the
response characteristics of the STF. Finally, a series of experimental modal analyses and cutting
experiments are conducted to verify the proposed forced vibration mechanism and STF suppression
theory.
The paper is organized as follows: the modal analysis theory of the thin-walled workpiece is
discussed in Section 2. The principle of vibration suppression of the thin-walled workpiece by the STF
is discussed in Section 3. EMA is conducted to verify the proposed forced vibration mechanism and
vibration suppression principle in Section 4. The cutting experiment and the analysis of the
experimental results are discussed in Section 5. The conclusion is presented in Section 6.

2 Modal analysis theory of a thin-walled workpiece influenced by multiple factors

The thin-walled workpiece has complex vibration characteristics during the cutting process due to
varying cutting positions, cutting force frequencies, and cutting force magnitudes. Chatter can be
avoided by selecting the machining parameters shown in the SLD diagram, but forced vibrations are
unavoidable when milling a thin-walled workpiece. Understanding the forced vibration mechanism of a
thin-walled workpiece is a prerequisite for vibration suppression. Modal analysis theory is an effective
method to analyse the forced vibration in milling machining. In this section, the influence of the above
three cutting factors on the forced vibration of the thin-walled workpiece during the milling process is
analysed in terms of modal theory, which provides theoretical guidance for explaining the forced
vibration mechanism and suppressing vibration in experiments.

2.1 Modal shape of the thin-walled workpiece

A natural characteristic of the thin-walled workpiece is the mode shape, which causes vibrations to
occur during the cutting process. This paper analyses the mode shape of the thin-walled workpiece
shown in Fig. 1 as an example, which is vital for the following modal analysis process and the
placement of the sensors in the experimental test. In Fig. 1, the bottom surface of the workpiece is fixed
with the following parameters: h = 50 mm, a = 120 mm, b = 100 mm, and d = 5 mm. Fig. 2 gives a
frequency response function diagram of the first six modes for the thin-walled workpiece.

Fig. 1. A thin-walled workpiece to be machined. Here, the system OXYZ is the coordinate system for

describing the mode shape of the workpiece. a, d, and h are the length, thickness, and height of the thin-walled

workpiece, respectively. b is the width of the workpiece base. The bottom surface of the workpiece is fixed at the
positions of the four symmetrical holes in the figure with the following parameters h = 50 mm, a = 120 mm, b =

100 mm, and d = 5 mm. The five points at the top of the thin-walled workpiece are selected to focus on the modal

shape of the workpiece in modal analysis, and to provide theoretical support for mode shape measurement.

Fig. 2. The modal frequencies and response amplitudes of the workpiece were analysed for the fixed workpiece

shown in Fig. 1. The frequency response function provides the theoretical basis for modal superposition theory.
Here, Mode 1 to Mode 3 are modes of the thin-walled workpiece at its natural frequency, which were obtained

from the finite element analysis.

According to the frequency response function diagram, the corresponding mode shape is
theoretically excited when the excitation frequency of the thin-walled workpiece reaches the natural
frequency. The coordinate system {OXYZ} is established on the thin-walled workpiece in Fig. 1, and
the coordinate relations in Fig. 3 give the mode shapes of the first three orders for the thin-walled
workpiece. According to the mode shape diagram, the sensors in the experiment should be placed at the
maximum deformation, such as the five positions shown in Fig. 1, so that more mode shapes of the
thin-walled workpieces can be measured.

Fig. 3. Mode shape of the thin-walled workpiece obtained by modal analysis of the thin-walled workpiece in Fig. 1.

To understand the vibration amplitude of each point in Fig. 1 at each mode, modal analysis theory was used to
analyse the workpiece in Fig. 1 and show the vibration degree of each point. The vibration amplitude is in

dimensionless form, which mainly reflects the relative magnitude at each position. (a) The first mode shape of the

thin-walled workpiece. (b) The second mode shape of the thin-walled workpiece. (c) The third mode shape of the

thin-walled workpiece. Here, the deformation values at each position in the figure are represented by the

coordinate system OXYZ established in Fig. 1.

2.2 Modal superposition theory of the thin-walled workpiece

As mentioned in the previous section, the corresponding mode shape will be excited when the
excitation frequency reaches the natural frequency. However, in actual operation conditions, the
excitation frequency is not the natural frequency in most cases, and the multi-order modes determine
the actual vibration shape. This conclusion also applies when the excitation frequency is the natural
frequency. In this case, the greatest contribution to the vibration shape is the mode shape corresponding
to the natural frequency, while the contribution of other modes can be neglected. To have a clear
understanding of the modal excitation process and modal superposition, the dynamics equations of the
thin-walled workpiece in Fig. 1 are considered, as shown in Eq. (1):

MX  CX  KX  F (t ) (1)

where M, C, K, and F(t) are the mass matrix, damping matrix, stiffness matrix, and input force matrix
of the thin-walled workpiece, respectively, and they are all symmetric arrays. X , X , and X are
acceleration, velocity, and displacement, respectively. For the convenience of the analysis, Equation 1
can be obtained by the Laplace transform, as follows:
(Ms 2  Cs  K ) X( s )  F( s ) (2)
The equation can be written as follows:
D( s) X( s)  F( s)  X( s)  F( s) D1 ( s) (3)
-1
where D(s) is the system matrix; then, its inverse matrix D (s) is the transfer matrix H(s) of the system,
which can be expressed as follows:

D* ( s) A( s )
D1 ( s)  H( s)   (4)
det D( s) det D( s)

where D* ( s ) is the adjugate matrix of D(s) and detD(s) is the determinant of D(s). The frequency
response function measured in the modal experiment is an estimation of the system transfer function
along the frequency axis. For convenience, the transfer matrix equation can be written as follows [66]:
m
Ak Ak
H( s) |s  j  H( j )   (  ) (5)
k 1 j  k j  k

where k is the pole; k is the complex conjugate of the pole; A k is the residue, which shows the
information of the mode shapes; and A k is the complex conjugate of the residue. The residue A k
can be expressed as follows:

A ( s ) k  p k v k v Tk (6)

where p k is the proportional factor; v k is the matrix of mode shape; v Tk is the transposition matrix
of v k ; Eq. (6) can be expanded and expressed as follows:
 a11k a12 k a13k   v1k v1k v1k v 2 k v1k v3k 
a   
 21k a 22 k a 23k   p  v 2 k v1k v2k v2k v 2 k v3 k  (7)
 a 31k a 32 k a 33k  k
 v3k v1k v3 k v 2 k v3 k v3 k 
   
   
where a11k , a12 k , a13k etc., are the elements of the residue matrix. v1k v1k , v1k v 2 k , v1k v3k etc. are
the values of the vibration shape of each point. Each row and column of the matrix in Eq. (7) contains
the mode shape information and the proportional factor.
From the above analysis, the transfer function matrix contains the mode shape information, and
the vibration characteristics X(s) are obtained when the transfer function matrix H(s) is convolved with
the external excitation F(s). According to the above process, the vibration characteristics are closely
related to the mode shape and external excitation. In actual machining, the mode shape of each order
for the thin-walled workpiece contributes to the overall vibration but with different degrees of
involvement. To explain the superposition process of each mode easily, the contribution relationship of
the first three modes in the actual vibration of the thin-walled workpiece in Fig. 4 can be considered. In
Fig. 4, the thin-walled workpiece is divided into many nodes, and point B with coordinate ( yB , zB )
among the nodes is selected for analysis. Fig. 4(a), (b), and (c) show the mode shapes of the first three
B B B
orders d mod e 1 , d mod e 2 , and d mod e 3 at point B, respectively. The mode shape at point B can be

expressed as follows:
  B A1B A1B
 d mod e 1  (  )
 j  1 j  1
 A B2 A 2B
d mod e 2  ( 
B
) (8)
 j  2 j  2
 A 3B A 3B
 d mod
B
 (  )
 j  3 j  3
e3

where A1B , A1B , 1B , and 1B are the mode shape parameters of point B in the first mode; A B2 ,
A B2 , 2B , and 2B are the mode shape parameters of point B in the second mode; and A1B , A1B , 3B ,
and 3B are the mode shape parameters of point B in the third mode.

Fig. 4. Schematic diagram of the modal excitation progress. To explain the superposition principle of each order of

modal action in the thin-walled parts milling process, the vibration amplitude of point B on the thin-walled

workpiece at excitation frequency f is used as an example to illustrate the principle. (a) The first mode shape value

of point B. (b) The second mode shape value of point B. (c) The third mode shape value of point B. (d) Cutting

force. (e) Frequency response function of point B at each mode. (f) Frequency response function of point B under

the influence of various modes. (g) The actual vibration value at point B under the influence of various modes.
B B B
Here, d mod e 1 , d mod e 2 , and d mod e 3 are the maximum mode deformation values of point B at mode 1, mode 2,

B B B
and mode 3, respectively. xmod e 1 (t ) , xmod e 2 (t ) , and xmod e 3 (t ) are the deformation values of point B in the first

mode, the second mode, and the third mode when the cutting frequency is f, respectively. F(s) is the Fourier

transform form of the cutting force. ODSB(t) is the actual deformation value at point B.
 Based on the description of the above equations, it can be observed that the mode shapes are
included in the transfer function, and they are natural characteristics of the thin-walled workpiece that
are excited to varying degrees in the vibration. According to Richardson’s theory [67], the actual
deformation of the thin-walled workpiece can be expressed as follows:

ODS(t )  FFT - 1 H( s)F( s) (9)

-1
where ODS(t) is the deformation value matrix of the thin-walled workpiece and FFT is the inverse
Fourier transformation. Then, the actual deformation value at point B is ODSB(t) [68], which can be
expressed as the superposition of the deformation values on each mode at point B, as follows:
ODSB (t )  xmod
B
e 1 (t )  xmod e 2 (t )  xmod e 3 (t )
B B
(10)
B B B
where ODSB(t) is the actual deformation value of point B and x mod e 1 (t ) , x
mod e 2 (t ) , and xmod e 3 (t ) are
the deformation values of point B in the first mode, the second mode, and the third mode when the
cutting frequency is f, respectively. They can be expressed as follows:

e 1 (t )  1 ( f,  , F ) d mod e 1
 xmod
B B

 B
 xmod e 2 (t )   2 ( f,  , F )d mod e 2
B
(11)
 xB
 mod e 3 (t )  3 ( f,  , F )d mod e 3
B

where 1 ( f,  , F ) ,  2 ( f,  , F ) , and 3 ( f,  , F ) are proportional factors representing the degree of

modal excitation by cutting forces at each mode. f,  , and F are the frequency of the cutting force, the
position factor of the cutting force on the thin-walled workpiece, and the amplitude of the cutting force,
respectively.
The above modal superposition process is shown in Fig. 4(d-g). Fig. 4(d) shows the time-domain
diagram of the actual cutting force for a section with principal frequency f. Under the excitation of the
cutting force, the response of each mode at point B for the thin-walled workpiece is shown in Fig. 4(e).
The responses of the first three orders of modal superposition are plotted in Fig. 4(f); then, the actual
deformation value of ODSB(t) at point B is shown in Fig. 4(g) for the thin-walled workpiece.
For point B on the thin-walled workpiece, the above modal superposition theory is analysed at an
excitation frequency of f. If the excitation frequency changes, the corresponding superposition result
will change, which will cause the actual vibration value of B to change. According to Eq. (1), the
magnitude of the excitation force is closely related to the acceleration, velocity, and displacement of the
actual vibration. Furthermore, in Eq. (11), the frequency of the cutting force, the position factor of the
cutting force on the thin-walled workpiece, and the amplitude of the cutting force directly determine
the contribution of each mode to the actual vibration value. Then, in the analysis of the modal
superposition theory, it can be observed that the cutting force frequency and the cutting force
magnitude affect the vibration of the thin-walled workpiece.

2.3 Modal node of the thin-walled workpiece

In addition to the above modal superposition theory, according to Cao et al. [68], the influence of
the excitation position on vibration is obvious in the construction field. In mode shapes of each order,
the position with the smallest mode shape value is called the modal node. According to Ref. [68],
excitation at the maximum deformation position of the mode shape can greatly excite the mode of this
order, while excitation at the modal node will not respond to the mode of this order. To discuss the
effect of excitation position on vibration, three excitation points are determined on the thin-walled
workpiece shown in Fig. 1 in Section 2.1. As shown in Fig. 5(a), an excitation of magnitude 200 N and
frequency 3000 Hz is applied to the three nodes in the figure, and harmonic response analysis is
conducted. Fig. 5(b), (c), and (d) show the finite element analysis results for excitation points 1, 2, and
3, respectively. According to the results, the excitation position affects the actual vibration of the
thin-walled workpiece. Accordingly, the change in cutting position affects the actual vibration
characteristics of the thin-walled workpiece.

Fig. 5. Schematic diagram of modal node theory verified by finite element simulation. To show the phenomenon of

forced vibration generated during the thin-walled workpiece milling process, finite element simulations with

different cutting excitation positions are used here to illustrate the node theory in forced vibration. That is, the

excitation position is located at the maximum deformation of the mode shape to increase the vibration of the mode,

and vice versa to weaken it. (a) Three excitation positions on the thin-walled workpiece. (b) The vibration
deformation value of the thin-walled workpiece with the excitation position is 1. (c) The vibration deformation

value of the thin-walled workpiece with the excitation position is 2. (d) The vibration deformation value of the

thin-walled workpiece with excitation position is 3. Here, the excitation force is 200 N, and the excitation

frequency is 3000 Hz. The workpiece size is shown in Fig. 1.

According to the above analysis of the thin-walled workpiece, it is known that the actual vibration
characteristics of the thin-walled workpiece are closely related to the cutting force position, cutting
force frequency and cutting force magnitude. When the excitation point is located at the position of the
maximum deformation of the mode shape, it can excite this mode to the maximum extent. When the
excitation frequency is close to the frequency of this mode, the mode can be excited. When the cutting
force increases, the forced vibration amplitude increases accordingly. Then, the actual vibration
characteristics can be explained according to the forced vibration mechanism analysed above.

3 Vibration suppression principle of shear thickening fluid (STF) in milling

According to the analysis in the previous section, the cutting force position, frequency and
magnitude can lead to the thin-walled workpiece having complex vibration characteristics. In the
milling process, the excitation force is a high frequency varying cutting force, and the cutting position
is constantly changing; thus, vibration suppression is a complex process. To suppress the above
complex vibration characteristics of the milling process, this paper proposes an assisted vibration
suppression method by adding an STF. In this section, the detailed characteristics of the STF and the
physical model of the impact force are given, which provide the theoretical basis for discussing the
vibration suppression effect of the STF in Section 4.

3.1 The characteristics of the STF

STF is a concentrated particle suspension formed by dispersing nano- or micron-scale particles

into a polar medium. Fig. 6(a-d) shows the complete process of STF action. Under certain shear
conditions, its viscosity increases significantly with increasing shear rate. The STF also has a fast
response and the process is reversible. The STF will change from a flowable liquid form to a
non-flowable solid form under high-speed impact [69]. In this paper, the thin-walled workpiece was
forced to vibrate under the action of the milling cutter, and its high-frequency impact on the STF
triggered local solidification of the STF [70].
Fig. 6. The impact resisting process of the STF. To illustrate the principle of the impact resistance of the STF and

its suppression effect on thin-walled parts under cutting excitation, the motion of microscopic particles in the STF

under cutting excitation is shown here. (a) In a static state. (b) Impact begin. (c) Violent impact. (d) The impact

ends. Here, this figure shows the four phases of motion changes for the nanosphere particles in the STF when they

are impacted. The small white balls in the figure represent the movement of the nanosphere particle. The position

of the cutter represents the position of the impact force during cutting.

Furthermore, the STF has a suppressive effect on the vibration of the thin-walled workpiece. As
shown in Fig. 7, this is a physical property of the STF selected for this paper, which is a mixture of
polyethylene glycol and SiO2. The physical property test data for the STF in Fig. 7 are from the
manufacturer, which shows an impact resistance similar to that of the STF in Ref. [71]. This
logarithmic coordinate diagram shows that the STF has high suppression characteristics for
high-frequency shocks. Unlike the study in Ref. [72], the STF selected in this paper has superior
response properties and storage convenience compared to corn starch fluid, and maintains the original
impact resistance properties in reuse.

Fig. 7. The impact response of the selected STF. To explain the impact resistance of the STF, the physical test
performance of the STF is given. Here, the horizontal coordinate indicates the shear rate, representing the impact

force. The vertical coordinate indicates the shear stress, representing the impact resistance of the STF. These

coordinate points in the figure are from the test data provided by the STF manufacturer, and two of them are

labelled.

3.2 Milling dynamic model with STF

The physical properties and shock response data of the STF were introduced in the previous
section. However, the principle of its suppression for forced vibrations still needs to be explained by a
dynamics model. In the research of Waitukaitis [70], a physical model of STF used to suppress the
impact of an aluminium rod was proposed, and the correctness of the model was verified by simulation
and experiment. Wang [72] introduced the model to milling for the first time. However, the boundary
conditions of the cavity workpiece are more restricted, and the forced variation in the milling process is
smaller. Therefore, Wang et al. considered the milling force of the cutter in combination with the
impact effect of the workpiece.
 In the thin plate workpiece milling process, which easily generates forced vibration, the workpiece
acting with the STF cannot be applied to the Waitukaitis model. However, it should consider the modal
analysis theory in Section 2. As shown in Fig. 8(a), this is the process of an aluminium block with
acceleration a 1 and mass m1 acting with an STF. According to the theory of Waitukaitis, the STF
solidifies directly below the aluminium block into a fast, effective, infinitely growing solidified mass
mSTF . Due to the impact of the aluminium block, the solidification region is not limited to the area
directly below the block but extends to the conical region, as shown in Fig. 8(a).
Similarly, when an aluminium block with the same mass but less acceleration impacts the STF, the
response is shown in Fig. 8(b). Then, when the two aluminium blocks are placed close together, the
response region generated is shown in Fig. 8(c). Furthermore, when an aluminium plate of mass m,
with each part having a gradually decreasing acceleration from the middle, impacts the STF, the
response generated is shown in Fig. 8(d). In this figure, the solidification area is located entirely
directly below the aluminium block, with no additional expansion area. If the acceleration gradually
decreases from the middle, then the force balance equation at this point can be expressed as follows:
N
a N dmSTF
 (m a )  m
i 1
i i STF  (
2 i 1 dt
vi )  mg = 0 (12)

with
 N
  ai a
 i 1 
 N 2 (13)
N
 mi  m
 i 1

Fig. 8. The impact response model with an aluminium block under different accelerations. To illustrate the impact

response of the STF at different accelerations of the thin-walled workpiece, the principle example of Ref. [70] is

combined here to analyse the impact resistance model for different conditions. (a) The impact response of the

aluminium block with acceleration a 1 . (b) The impact response of the aluminium block with acceleration a 2 . (c)

The impact response of two aluminium blocks with different acceleration values. (d) The impact response of a
piece of the aluminium plate with each part having a gradually decreasing acceleration from the middle. Here,

m1 and m 2 are the masses of the aluminium blocks with acceleration a 1 and acceleration a 2 , respectively.

z , r2 , and za 2 are the dynamics model parameters of the STF. a is the acceleration in the middle of the

aluminium plate.

where m i is the mass of the i-th part of the divided aluminium block with mass m; a i is the
acceleration of the aluminium block with mass m i . According to the research of Hong et al. [73], the
acceleration of vibration in the plate depends on the frequency, and the effect of the vibration frequency
f i of the i-th aluminium block on the acceleration a i can be represented by a i ( f i ) ; vi is the speed
of the aluminium block with mass m i ; N is the number of aluminium block divisions with mass m;
and mSTF is the mass of the solidification region where the STF is impacted. To calculate the mass of
mSTF , Fig. 8(b) is analysed as an example. This extended region is a cone with a bottom radius za 2 .
The value of za 2 is related to the displacement z of the aluminium block from its initial position
and can be expressed as follows:

za 2  k z  kq (t ) (14)

where k is the correlation coefficient and q (t ) is the displacement of the aluminium block with time.
Then, according to the above analysis, the mass of the extended region in Fig. 7(d) can be expressed as
follows:

mSTF  C(1/ 3)  kq (t )  r2 2 kq (t ) (15)

where C and k are constant coefficients related to the viscosity of the shear fluid;  is the density of
the STF; and r2 is the distance between the edge position and the centre of the aluminium block of
mass m1 . q (t ) is the displacement of the aluminium block with time.
According to the above analysis process, when the cutter causes forced vibration of the workpiece
during machining, the above impact process will occur between the workpiece and the STF. As an
impact analysis example, a thin-walled workpiece generating the second mode shape is shown in Fig.
9(a). For a workpiece that generates the second mode shape, a part of the STF solidification region for
the process of impacting with the STF is shown in Fig. 9(b) and (c). In this figure, Fig. 9(b) is the side
view and Fig. 9(c) is the top view.
The acceleration at the maximum deformation of the second mode is the largest and decreases
gradually towards the acceleration at 0. Then, the solidification region can be deduced according to the
analysis process of Fig. 8. Furthermore, the solidification region on the right side is obtained as a 1/4
ellipsoidal region. The mass of the right solidification region can be expressed as follows:

mSTF  C(1 / 4)   kq (t )  R kq (t )l (16)

where mSTF is the STF mass of the solidification area; C and k are constant coefficients, respectively,
related to the viscosity of the shear fluid. l is the acceleration range on the thin-walled workpiece. R is
the radius of the cutter; q (t ) is the displacement of the aluminium block with time.
Here, the force balance state should consider the cutting force effect. To calculate the cutting force
F(t), consider an infinite division of the cutter into many cutting elements, as shown in Fig. 10.
According to Ref. [74], the cutting force of each element can be expressed as follows:

 dFt ( (i, j, t ))  g ( (i, j, t ))( K tc h( (i, j, t ))  K te )dz

 (17)
dFr ( (i, j, t ))  g ( (i, j, t ))( K rc h( (i, j, t ))  K re )dz

where dFt ( (i, j , t )) and dFr ( (i, j , t )) are the tangential and radial cutting forces on the j-th axial
disk element of the i-th tooth at time t, respectively; dz is the thickness of each axial cutting element;
K tc and K rc are the shearing specific cutting force coefficients in the tangential and radial directions,
respectively; K te and K re are the ploughing specific cutting force coefficients in the tangential and
radial directions, respectively;  (i, j , t ) is the location angle of the cutter; h( (i, j , t )) is the
instantaneous undeformed chip thickness value at the location angle  (i, j , t ) ; and g ( (i, j , t )) is
the window function used to indicate whether the current axial disk element is involved in cutting and
can be defined as follows:

 g ( (i, j, t ))  1,
 st, i , j   (i, j , t )  ex, i , j
 (18)
 g ( (i, j, t ))  0,
  (i, j, t )＜st, i , j or  (i, j, t )＞ex, i , j

where st, i , j and ex, i , j are the entry angle and exit angle on the j-th axial disk element of the i-th
tooth at time t, respectively.

Fig. 9. The impact response of the STF to second-order modal deformation of the thin-walled workpiece. To

illustrate the impact response of the STF under different modal vibration shapes of the thin-walled workpiece, the

second-order modal vibration deformation is used here as an example, and the STF impact solidification region is

analysed by combining the principles in Fig. 8. (a) Shape of the thin-walled workpiece. (b) Side view of the

response region. (c) Top view of the response region. Here, the workpiece size and fixing method are the same as

in Fig. 1. The response region of the STF is established based on Fig. 8. kq(t) and l are the size parameters of the

STF response model determined by the vibration information of the workpiece.

 After obtaining the cutting force of each cutter element, it should be projected to the cutter
coordinate system and superimposed to obtain the force in each direction of the cutter. In Fig. 10, the
system Oc Xc Yc Zc  is defined as the cutter coordinate system attached to the centre of the cutter end
surface. Although the cutting force model has an error when compared with the real value, it can be
shown that the cutting force is an exciting force with high frequency variation, which can excite the
forced vibration of the thin-walled workpiece.

Because the stiffness of the workpiece along the X c direction is much greater than the stiffness
of the workpiece along the Yc direction, the cutting force acting on the workpiece by the cutter can be
expressed as the force Fc, x (t ) in the X c direction. Fc, x (t ) can be obtained by superimposing the
radial and tangential cutting force projections of each element shown in Fig. 10 onto the cutter
coordinate system. Then Fc, x (t ) can be expressed as follows:
N M
Fc, x (t )    dFt ( (i, j, t ))sin( (i, j, t )  dFr ( (i, j, t )) cos( (i, j, t ))  (19)
i 1 j 1

where N and M are the number of angular integration steps and cutter teeth, respectively. Then the
dynamic balance equation for the thin-walled workpiece generating the second mode shape
characteristics can be analysed by considering both Eq. (19) and Eq. (15). The above analysis method
is still applicable when other vibration characteristics are generated by the superposition of various
modes of the thin-walled workpiece. According to the above analysis, the suppression process of the
STF on the complex vibration characteristics of the thin-walled workpiece can be represented in Fig.
11.

Fig. 10. Calculation method of cutting force in thin-walled workpiece milling. Here, the cutting force model is

constructed mainly to illustrate that the cutting force is a periodic dynamic characteristic that acts on the workpiece

with high frequency variation. The factors influencing the cutting forces are shown in the model parameters. In the

cutting force model, the cutter is infinitely divided into many cutting elements. The cutting force can be obtained

by computing the sum of the element cutting force vectors. System Oc X c Yc Zc  is the cutter coordinate system

attached to the centre of the cutter end surface. Fc, x (t ) and Fc, y (t ) are the cutting forces on the workpiece

applied by the cutter in the X c and Yc directions, respectively.  (i, j , t ) and  are the location angle of the

cutter and the angular velocity of the cutter, respectively. dz is the thickness of each axial cutting element.
dFt ( (i, j , t )) and dFr ( (i, j , t )) are the tangential and radial cutting forces on the j-th axial disk element of the

i-th tooth at time t, respectively.

In Fig. 11, the spindle speed n, axial depth of cut a p , radial depth of cut ae , and feedrate v of the
cutter determine the magnitude of the cutting force and the cutting force frequency f of the cutter on the
workpiece. The relationship between these parameters and the cutting force is described in the cutting
force model of this section. Under the impact of the cutting forces, the modes of the thin-walled
workpiece, which are determined by the intrinsic properties M, C, and K, are excited to different
degrees, resulting in different vibration characteristics. As the cutting position changes, the vibration
characteristics also change. The generated vibration characteristics can be classified as displacement X,
velocity X , and acceleration X . They are different at different positions on each thin-walled
workpiece, which shows the complexity of the vibration characteristics for the thin-walled workpiece.
These complex vibration characteristics act on the STF, causing different degrees of local solidification
responses at different positions of the STF, which in turn produce different suppression processes for
different vibration characteristics. From the STF solidification region parameters and the force balance
equation, it can be observed that the frequency and magnitude of the vibration are crucial to the impact
response force. Further analysis shows that the STF has different suppression effects for different
cutting frequencies, cutting force magnitudes, and cutting force positions. Therefore, the STF can
suppress the complex forced vibration characteristics of the thin-walled workpiece.

Fig. 11. Vibration suppression process of the thin-walled workpiece with the influence of multiple parameters. To

illustrate the suppression process of the STF for the thin-walled workpiece vibration during the milling process, the

figure shows the interaction relationship between the parameters of each section in the vibration generation and

suppression process. Here, n, a p , ae , v, f, and F(t) are the spindle speed, axial depth of cut, radial depth of cut,
feed speed, cutting force-frequency, and cutting force, respectively. M, C and K are the mass matrix, the damp

matrix, and the stiffness matrix of the thin-walled workpiece, respectively. x if and y if are the coordinates of the

vibration point on the workpiece. X , X , and X are the displacement, velocity, and acceleration of the
generated vibration characteristics, respectively. C, k, q(t), and r are the solidification parameters in the STF

response model. mSTF dt is the change rate of the solidification region. a i ( f i ) is the vibration acceleration at

the excitation frequency f i .

4 Experimental modal analysis

According to the analysis in Section 2, the vibration characteristics of the thin-walled workpiece
are determined by the cutting frequencies, cutting force magnitudes, and cutting force positions.
According to the analysis in Section 3, the STF can suppress the vibration characteristics under the
influence of these factors. However, these two sections only discuss the analysis of the physical model.
The actual thin-walled workpiece and STF effects still need further analysis. In this section, the
responses under different excitation positions are compared by hammering the workpiece at different
positions. The effect of STF on the response amplitude is observed by adding STF and hammering. The
correctness of the proposed theoretical and suppression methods is analysed by these comparisons in
EMA, and the experimental analysis of cutting for the thin-walled workpiece is discussed in the next
section.
EMA is an effective method for extracting and analysing the physical characteristics of
workpieces during machining. In this paper, the thin-walled workpiece has two symmetrical
thin-walled plates, as shown in Fig. 12(a). The experimental setup is shown in Fig. 13. On the one hand,
this type of workpiece allows convenient STF filling, and on the other hand, the two thin-walled plates
can be compared in cutting experiments to avoid the constraint error caused by clamping. Two acrylic
plates are installed at the ends of the two thin-walled plates in Fig. 12(a), which prevents the overflow
of the filled STF. As shown in Fig. 12(b), there is a 1 mm gap between the thin-walled plates of the
thin-walled workpiece and the acrylic sheet so that the acrylic sheet does not change the physical
characteristics of the thin-walled workpiece. The volume of the filled STF in Fig. 12(c) is
approximately 220,000 cubic millimetres. Moreover, according to the conclusions in Ref. [70], the STF
is partially solidified internally by impact, and the solidification effect is recovered with the release of
the impact force. Therefore, the STF only acts as a support for the thin-walled workpiece.
Fig. 12(c) shows a diagram of the experimental setup with the STF. In this figure, the STF is
placed in a 0.01 mm thick polyethylene film and then placed in the middle of the thin-walled
workpiece. Finally, the thin-walled workpiece to be measured is fixed in the dynamometer, as shown in
Fig. 13. The LMS SCADAS dynamic acquisition equipment is used for signal acquisition and analysis,
as shown in Fig. 14. The acceleration sensor Dytran 3224A3 was used to acquire the vibration signals
of the thin-walled workpiece. LMS Test. Lab 17 software was used to analyse the acquired vibration
signals. In the experiment, the thin-walled workpiece without an STF added is shown in Fig. 12(b), and
the thin-walled workpiece with an STF added is shown in Fig. 12(c), and both are excited by the
impact hammer. When the excitation point is over point 5, Fig. 14(a) and (c) show the frequency
response functions of the thin-walled workpiece with and without an STF added, respectively. In these
two figures, the natural frequencies of the four modes for the thin-walled workpiece and their
corresponding amplitudes are selected by the LMS Test. Lab 17 software. The mac matrices [75]
shown in Fig. 14(b) and (d) verify that the natural frequencies selected in Fig. 14(a) and (c) are correct.
Similarly, Fig. 14(e) and (g) show the frequency response function and the natural frequency,
respectively, when the impact position is over point 4. The Mac matrices shown in Fig. 14(f) and (h)
verify that the natural frequencies selected in Fig. 14(e) and (g) are correct.

Fig. 12. Experimental model and clamping setup. To enable researchers to reproduce the experiments in this paper,

the clamping method and the placement of the STF are shown in the figure. (a) The experimental model. (b) Set up.

(c) Set up with STF. Here, the workpiece selected for the experiment is a workpiece with two thin-walled plates,

which are symmetric for the contrast experiment. Two acrylic plates are placed at both ends of the two thin-walled

plates to hold the STF without affecting the physical properties of the thin-walled plates. There is a 1 mm gap
between the acrylic plate and the thin-walled plate. The STF is placed between the thin-walled plates. The

impact/cutting area is located at the top of the thin-walled workpiece. The five acceleration sensors are placed

under the impact/cutting area, and the locations of the five acceleration sensors are the same as in Fig. 1.
Fig. 13. Experimental setup. To enable researchers to reproduce the data acquisition process in this paper, the

figure shows the connections of the data acquisition devices. Here, the vibration signal is received by the LMS

SCADAS data acquisition instrument through the acceleration sensor and analysed by the LMS Test. Lab 17

software on the computer. The cutting force signal is collected by the computer through the dynamometer.
Fig. 14. EMA results for the thin-walled workpiece. To understand the physical characteristics of the thin-walled

workpiece in the operating condition and the impact resistance effect after adding the STF, the EMA method is

used here for this experimental process, and this experimental result is obtained based on the apparatus shown in

Figs. 12 and 13. (a) The frequency response functions of the thin-walled workpiece without STF added at point 5.

(b) The mac matrix of modes selected at point 5 without STF added. (c) The frequency response functions of the

thin-walled workpiece with STF added at point 5. (d) The mac matrix of modes selected at point 5 with STF added.

(e) The frequency response functions of the thin-walled workpiece without STF added at point 4. (f) The mac
matrix of modes selected at point 4 without STF added. (g) The frequency response functions of the thin-walled

workpiece with STF added at point 4. (h) The mac matrix of modes selected at point 4 with STF added. Here, the

mac matrix is the judgment of mode selection. The physical characteristics of the thin-walled workpiece can be

obtained from this EMA result, and its impact resistance is significantly enhanced by adding STF. The mac matrix

shows that the selected modes have high mutual independence, which indicates that the modes are correctly

identified.

The EMA results are shown in Fig. 14. The comparison of Fig. 14(a) and (e) shows that the
natural frequency of the thin-walled workpiece does not vary with the change in the impact position,
which also indicates that it is a natural characteristic of the workpiece. In fact, the natural frequency is
determined by the clamping method and the physical properties, i.e., the mass, damping, and stiffness
of the thin-walled workpiece. Generally, when the workpiece is clamped, its natural frequency is
determined.
According to the comparison of Fig. 14(a) and (c), the acrylic plate and STF do not change the
natural frequency of the thin-walled workpiece, which indicates that the acrylic plate and STF do not
have boundary constraints on the thin-walled workpiece. In this paper, the acrylic plate only provides
support for the STF so that the STF and the thin-walled workpiece are fully fitted to reduce the
vibration. According to the comparison of Fig. 14(a) and (e), the amplitudes of the modes are different
for different impact positions. During the actual cutting process, the cutter constantly changes its
relative position to the workpiece as the cutting progresses, which is equal to the impact of the cutter at
different positions on the thin-walled workpiece. This process increases the complexity of the vibration
phenomenon during milling, and the EMA reflects the principle of this phenomenon to some extent.
These experimental results verify the modal node theory in Section 2.3 and provide theoretical support
for the cutting experiments. The mac matrix shown in Fig. 14(b), (d), (f), and (h) is a method to judge
the correctness of the selected mode, which is generated by the LMS software. Undoubtedly, the
correlation of the same mode is 100%. The correlation between two independent modes should be as
small as possible so that these two modes can be called two natural modes of the thin-walled workpiece.
The frequency response functions shown in Fig. 14(a), (c), (e), and (g) show that the selected modes
are located at the peaks. However, some peaks are not judged as modes due to the high correlation
between the mode and the mode already selected. From the modes that have been chosen, it can be
observed that the modes are weakly correlated with each other. The mac matrix shows that the modes
selected in the EMA experiments in this paper are correct.
However, Fig. 14 also shows that the STF has different suppression effects for different frequency
response amplitudes. This paper counts the different response amplitudes and suppression effects of the
five impact points, and the statistical results are shown in Fig. 15.
As shown in Fig. 15, the STF is more effective in suppressing all frequency responses with large
amplitudes. The above EMA results agree with the theory in Section 3.2. The EMA results also verify
the suppression characteristics of the STF for high impact. In addition, the LMS Test. Lab 17 software
analysed the collected vibration signals and obtained the vibration shape for each mode, and the results
agree with the finite element analysis results given in Section 2.1.

Fig. 15. Frequency responses and suppression effects of different modes at different impact points in the EMA.

Here, consider the vibration amplitude of the first four modes when the thin-walled workpiece is hammered at

different positions. The suppression effects of the STF on different modes at different cutting positions were

calculated. The STF is found to be more effective in suppressing the vibration characteristics with a large vibration

amplitude.

5 Cutting experiment and verification

In the above EMA, this paper obtains the frequency response function for each mode of the
thin-walled workpiece and extracts the physical parameters of the thin-walled workpiece. Section 4
analyses the response effect of the thin-walled workpiece with and without STF to obtain the principle
of vibration suppression of the thin-walled workpiece by STF. However, in actual cutting, the
excitation for the thin-walled workpiece is a high frequency varying cutting force. EMA cannot fully
simulate the actual machining situation, so it is necessary to conduct an experimental analysis of the
cutting operation. In the cutting experiment, the workpiece does not need to be clamped again, and only
the thin-walled workpiece shown in Fig. 12 is cut. In this way, the physical parameters of the
thin-walled workpiece extracted from the EMA can be used for cutting experiments [76]. In addition,
clamping and positioning errors can be avoided.
As shown in Fig. 16 (g), the thin-walled workpiece in Fig. 12 is divided into five positions
corresponding to five sensors, namely, sensor 1, sensor 2, sensor 3, sensor 4, and sensor 5, and five
cutting positions, namely, position 1, position 2, position 3, position 4, and position 5. In the cutting
experiment, five positions were cut with down milling, and the vibration acceleration signals at each
position were collected. The selected cutter is a two-edged carbide cutter with a diameter of 12 mm and
a helix angle of 55 degrees. The selected feedrate is 400 mm/min, the spindle speed is 5000 r/min, the
radial cutting depth is 0.1 mm, and the axial cutting depth is 6 mm. Since the thin-walled workpiece in
this paper is symmetrical, only the vibration signals during cutting at position 1, position 2, and
position 3 are chosen to analyse the proposed theory. As shown in Fig. 16(a-c) and Fig. 16(k-m), the
wavelet transform of the time-domain response represents the overall vibration response at the position,
which contains white noise excitation. As shown in Fig. 16(d-f) and Fig. 16(h-j), the frequency-domain
transform of the cross-power, which is the response with respect to the reference point, does not
contain white noise excitation.
According to Fig. 16(d) and (e), the frequency domain transform of the cross-power for the
thin-walled workpiece is different at different cutting positions. Different frequency response diagrams
correspond to different mode shape superpositions, which agrees with the modal node theory in Section
2.3 of this paper. Therefore, both EMA and cutting experiments show that the vibration shape varies
with the cutting position.
Fig. 16. Frequency response of the thin-walled workpiece at different cutting positions. In actual machining, the

high frequency varying cutting force is different from the hammering force of EMA. To test the vibration of the

thin-walled workpiece when cutting at different positions, experiments are conducted here based on the setups in

Figs. 12 and 13. Wavelet analysis was used to check the variation in vibration with time and frequency at different

points. (a) Wavelet transform of time domain response with cutting position 1 and sensor 2. (b) Wavelet transform

of time domain response with cutting position 2 and sensor 2. (c) Wavelet transform of time domain response with

cutting position 3 and sensor 2. (d) Frequency domain transform of cross-powers with cutting position 1 and
sensor 2. (e) Frequency domain transform of cross-powers with cutting position 2 and sensor 2. (f) Frequency

domain transform of cross-powers with cutting position 3 and sensor 2. (g) Cutting position and sensor position of

the thin wall workpiece. (h) Frequency domain transform of cross-powers with cutting position 2 and sensor 1. (i)

Frequency domain transform of cross-powers with cutting position 2 and sensor 2. (j) Frequency domain transform

of cross-powers with cutting position 2 and sensor 3. (k) Wavelet transform of time domain response with cutting

position 2 and sensor 1. (l) Wavelet transform of time domain response with cutting position 2 and sensor 2. (m)

Wavelet transform of time domain response with cutting position 2 and sensor 3. Here, the cutter cuts at positions

1, 2, and 3. The selected cutter is a two-edged carbide cutter with a diameter of 12 mm and a helix angle of 55

degrees. The selected feedrate is 400 mm/min, the spindle speed is 5000 r/min, the radial cutting depth is 0.1 mm,
and the axial cutting depth is 6 mm. The wavelet transform of the time-domain response represents the overall

vibration response at the position, which contains the white noise excitation.

The different modes of the workpiece are excited due to the cutting position and cutting frequency.
The frequency responses of the first and second modes are greatest when cutting at position 1
compared to cutting at other positions. This is because cutting position 1 is the maximum deformation
for both the first and second modes. Moreover, the cutter frequency chosen in this paper is closer to the
first two modes, and the frequency domain diagram is shown under the combined effect of cutting
frequency and cutting position. These experimental phenomena are consistent with the modal analysis
theory of the thin-walled workpiece presented previously. Furthermore, the spindle speed and feed
speed can be reduced at position 1 and position 5 to reduce the vibration phenomenon caused in actual
machining.
In addition, the wavelet transform of the time domain response in Fig. 16 includes white noise and
clamping effects, which reflect the overall real-time vibration at this sensor. However, some
phenomena of forced vibration for the thin-walled workpiece can be discovered from it. For example,
when cutting at point 2, the vibration shape at each point is superimposed by each mode. In this case,
all modes contribute at sensor 1, but the second mode does not contribute at sensor 3, and the third
mode does not contribute at sensor 2. Thus, sensor 1 in Fig. 16(k) has a larger amplitude than sensors 2
and 3. Furthermore, in actual machining, the vibration suppression position can be adjusted according
to the change in cutting position in combination with the modal shape.
To illustrate the effect of the STF in suppressing the vibration for the thin-walled workpiece in
actual cutting, a comparison of vibration signals during down cutting at position 1 is shown in Fig. 17.
Fig. 17(a), (c), and (e) show the wavelet transform of the time-domain response at sensor 1, sensor 2,
and sensor 3, respectively, when cutting at position 1 in Fig. 16 without adding the STF. Fig. 17(b), (d),
and (f) show the results of the comparison experiment, which was conducted at the symmetry of the
thin-walled workpiece.
According to the comparison of vibration signals shown in Fig. 17, the STF has a suppressing
effect on the vibration of the thin-walled workpiece, especially for high impact and high frequency.
According to the theory in Section 3.2 [70], the impact resistance of the STF is closely related to the
local solidification quality, which is directly determined by the impact force applied to the STF.
Therefore, the STF suppression method proposed in this paper can effectively suppress the complex
vibration characteristics, especially for high impact and high frequency.

Fig. 17. The vibration amplitude of the thin-walled workpiece with or without STF in the down milling process.

After filling the STF, the corresponding cutting experiments are performed at the symmetrical positions in Fig. 12.

The response results are wavelet transformed, and the cutting results of the thin-walled workpiece without STF

support and with STF support are compared. (a) The vibration amplitude of position 1 without the STF. (b) The

vibration amplitude of position 1 without the STF. (c) The vibration amplitude of position 2 without the STF. (d)

The vibration amplitude of position 2 without the STF. (e) The vibration amplitude of position 3 without the STF.

(f) The vibration amplitude of position 3 without the STF. Here, the positions correspond to those in Fig. 16. The
machining parameters are the same as those in Fig. 17. The vibration signals are collected at cutting position 1.

The figures are wavelet transforms of the time-domain response used to represent the overall vibration response at

the position, which contains white noise excitation.

Fig. 18. Surface quality inspection experiment. A Mitutoyo SJ-210 profilometer is used to measure the surface

roughness of the machined surface. The surface roughness of the machined surface with and without the STF

support is measured separately here.

Finally, the roughness of the machined surface was measured to evaluate the efficiency of the
vibration suppression method in this paper. Fig. 18 shows the setup diagram of the roughness
measurement experiment. In this paper, the Mitutoyo SJ-210 profilometer is used to measure the
surface roughness of the machined surface. Fig. 19 shows the surface roughness at positions 3, 4, and 5
in the cutting process with and without the STF. Then, the surface roughness can be calculated. The
calculation results are shown in Table 1.
Table. 1 Roughness measurement of the machined surface

Position Position 3 Position 4 Position 5

Machined without SFT 0.391 1.036 1.352
Machined with SFT 0.162 0.172 0.219

According to Table 1, the surface roughness at position 3 is lower than that at the other positions
due to its lower forced vibration. In addition, position 5 cutting is more likely to generate forced
vibration, agreeing with the modal node theory in Section 2.3. Vibration suppression with the STF at
the same location can reduce surface roughness, which shows that the method in this paper can
effectively suppress the forced vibration and improve the surface quality.
Fig. 19. Surface profile measurement results without STF and with STF. The results of the measurement

experiments in Fig. 18 are plotted, and the surface roughness index Ra can be calculated from the range and
magnitude of the profile height variation. Consequently, the surface quality of the milling process with and without

STF can be compared. (a) Without STF at position 3. (b) With STF at position 3. (c) Without STF at position 4. (d)

With STF at position 4. (e) Without STF at position 5. (f) With STF at position 5. Here, the positions correspond to

those in Fig. 16.

6 Conclusions

To improve the surface quality of the thin-walled workpiece in the milling process, this paper
proposes a forced vibration mechanism for the thin-walled workpiece and develops a vibration
suppression method using STF. Through a series of experimental modal analyses and cutting
experiments, the following conclusions can be obtained.
 The forced vibration mechanism for the thin-walled workpiece proposed in this paper can explain
the complex vibration characteristics of the thin-walled workpiece and provide guidance for practical
machining. When the cutter is cutting at different positions, the workpiece is excited to a different
degree for each mode. The actual vibration shape demonstrated by these modes is superimposed to
form the complex vibration characteristics of the thin-walled workpiece. When the selected machining
parameters are different, the degree of modal excitation varies for different modes. Therefore, the
forced vibration characteristics of the thin-walled workpiece are closely related to the cutting position,
cutting force frequency, and cutting force magnitude. This forced vibration mechanism can effectively
explain the complex vibration characteristics in the milling process of the thin-walled workpiece, and it
is verified in the examples given in this paper.
Based on this mechanism, the proposed vibration suppression method using STF can effectively
suppress the forced vibration characteristics in the milling process of the thin-walled workpiece. The
response force of the STF is different under different impact characteristics. The vibration
characteristic parameters at each position of the thin-walled workpiece correspond to the response force
parameters of the STF, and the STF can effectively reduce its complex vibration characteristics. The
adaptive response characteristics of the STF to different impacts are verified in the experiments of this
paper. In actual machining, this vibration suppression method can also provide vibration suppression
for the weak position in the large thin-walled workpiece.
Overall, the results of this research provide further guidance for optimizing machining parameters
in thin-walled workpiece milling. The experiments in this paper were validated using thin-walled plates,
but the conclusions are equally applicable to curved surface analysis. In future studies, the STF will be
wrapped with plastic film and placed in the turbine blades. Then, the effect of the STF on forced
vibration suppression in the machining of the complex workpiece will be investigated.

Declaration of Interests

The authors declare that they have no known competing financial interests or personal
relationships that could have appeared to influence the work reported in this paper.

CRediT author statement

Xing Yuan: Methodology; Software; Writing – review & editing. Shuting Wang:
Supervision; Conceptualization; Project administration. Xingyong Mao: Methodology;
Investigation; Formal analysis. Hongqi Liu: Data curation; Formal analysis, Resources.
Zhaoshun Liang: Visualization; review. Qiushuang Guo: Validation; review. Rong Yan:
Funding acquisition; Project administration.
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