Chatter suppression for milling based on local resonance elastic metamaterials

Abstract

One of the most important features of metamaterials is the generation of band gaps, where waves cannot propagate through. In particular, local resonance metamaterials are widely used in the field of vibration suppression due to their ability to generate band gaps in the low frequency range. In this paper, we try to apply the concept of metamaterials to the milling process, and propose two new local resonance metamaterial tool structures to realize chatter suppression of slender tools. Two types of local resonance milling tools are designed for different machining scenarios and the band gaps of the proposed structures are calculated by the transfer matrix (TM) method. Then, a combined analytical-experimental method is used to determine the tool tip frequency response functions (FRFs) for the spindle-tool holder-tool configuration, where the full receptances of the local resonance milling tool are obtained through the spectral element method (SEM). The corresponding chatter stability lobe diagrams (SLDs) are constructed and the results show that the critical depth of cut and the proportion of stable region are significantly enhanced by the local resonance milling tool. Finally, the milling performance of the new tool is verified via a set of milling tests. The results show that the proposed structures can effectively suppress chatter and improve the surface quality of the workpiece.