Design and Simulation of Long Slender end Mill Embedded with Passive Damper

Milling operations associated with chatter vibrations usually result in poor surface quality, tool wearing and low efficiency. For some high speed cutting processes, such as the milling of aerospace products, long slender end milling tools are applied for the parts with deep pockets and thin ribs. Cutting tool with large length-diameter ratio is a significant factor leading to chatter, and damping cutter embedded with single degree of freedom (SDOF) passive damper is investigated. Finite element model of the damping cutter is established by ANSYS, and modal analysis and harmonic response analysis are performed to verify the damping effect of the tool. Simulation results show that the amplitude of the frequency response of function (FRF) is decreased 80%and critical depth of cut is increased by 2.7 times for the proposed damping tool compared to the common solid tool with the same length-diameter ratio, which therefore cause the enhancement of machining stability.