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An experimental evaluation of particle impact dampers applied on the tool for milling of hardened steel complex surface

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Abstract

In the manufacturing of dies and molds, vibrations may represent serious problems, since the finishing tool used is usually slender (high length/diameter ratio) in order to machine deep cavities with complex geometries, typical of these products. Vibration is an undesirable phenomenon in any machining operation as it can lead to poor surface finish, low material removal rate, and high tool wear rate. Impact dampers have been put into the tools as a method for reducing vibration in machining processes. Damping occurs through energy dissipation and linear momentum exchange during intermittent collisions between the main structure (in this case the milling tool) and a free mass (spheres or cylinders placed within a tool cavity). Although efficient, these types of dampers are highly nonlinear. Thus, the aim of this work is to analyze the effect of different materials and geometries (steel spheres, tungsten spheres and steel cylinders) acting as impact damper elements inside a ball nose end milling tool. To perform this task, a comparison of commercial tool holders and dampened tool holders was done in the milling of a convex D6 steel surface, comparing commercial tool holders with dampened ones. The results showed that the tools with impact dampers generated lower values of roughness in the workpiece (around 30% of the value observed in the conventional steel tool holder for the case of steel cylinders and around 40% for both spheres) and presented lower levels of vibration when compared to the same tool without the impact damper, mainly in the machining of workpiece regions where radial and tangential forces are predominant. The tool which used tungsten spheres as damper elements generated roughness surfaces similar to those obtained with steel spheres, while the tool which used steel cylinders only generated lower roughness in the regions where the axial force component is not predominant, which shows that its performance is highly dependent on the resulting force direction.

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Acknowledgements

The authors would like to thank the “Conselho Nacional de Desenvolvimento Científico e Tecnológico - CNPq” for providing the scholarship,“Fundação de Amparo à Pesquisa do Estado de São Paulo – FAPESP” and DEMM-FEM/UNICAMP.

Funding

The research leading to these results received funding from “Conselho Nacional de Desenvolvimento Científico e Tecnológico—CNPq” under Grant Agreement No 131984/2018–7 and “Fundação de Amparo à Pesquisa do Estado de São Paulo – FAPESP” (2013/00551–7).

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  1. School of Mechanical Engineering, University of Campinas, Campinas, SP, Brazil

    Victor Rossi Saciotto & Anselmo Eduardo Diniz

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  1. Victor Rossi Saciotto
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  2. Anselmo Eduardo Diniz
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Correspondence to Victor Rossi Saciotto.

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Saciotto, V.R., Diniz, A.E. An experimental evaluation of particle impact dampers applied on the tool for milling of hardened steel complex surface. Int J Adv Manuf Technol 119, 7579–7597 (2022). https://doi.org/10.1007/s00170-022-08782-4

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