Feasibility study of nonlinear tuned mass damper for machining chatter suppression

In order to improve the performance of the tuned mass damper (TMD) for machining chatter suppression, a new-type of nonlinear TMD is proposed in this paper. Compared with the common linear TMD, the nonlinear TMD is equipped with an additional series friction-spring element. The capability of the nonlinear TMD in suppressing machining chatter vibration is investigated in this paper. The harmonic balancing method (HBM) is used to estimate the frequency response function (FRF) of the machining system to which the nonlinear TMD is attached. Considering the special nature of the machining stability problem, the optimal design parameters of this nonlinear TMD are those that minimize the magnitude of the real part of the FRF of the nonlinear TMD damped machining system. This paper also demonstrates the performance of the optimally tuned nonlinear TMD for machining stability improvement by calculating the stability diagrams for the milling of the nonlinear TMD damped workpiece. The calculation results show that more than 30% improvement in the critical limiting cutting depth can be obtained, compared to the optimally tuned linear TMD.