An electromagnetic semi-active dynamic vibration absorber for thin-walled workpiece vibration suppression in mirror milling

doi:10.1007/s10483-024-3132-7

Abstract

Abstract:

As critical components of aircraft skins and rocket fuel storage tank shells, large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness. To address these challenges, we propose a novel tunable electromagnetic semi-active dynamic vibration absorber (ESADVA), which integrates with a magnetic suction follower to form a followed ESADVA (follow-ESADVA) for mirror milling. This system combines a tunable magnet oscillator with a follower, enabling real-time vibration absorption and condition feedback throughout the milling process. Additionally, the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator, which alters the distance between magnets. This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference. The frequency shift characteristics and vibration absorption performance are comprehensively investigated. Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool, resulting in a vibration suppression rate of approximately 47.57%. Moreover, the roughness of the machined surface decreases by 18.95%, significantly enhancing the surface quality. The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.

Key words: semi-active dynamic vibration absorber (SADVA), mirror milling, self-sensing, vibration absorption tuning, thin-walled workpiece

2010 MSC Number:

70J35

Jianghua KONG, Bei DING, Wei WANG, Zhixia WANG, Juliang XIAO, Hongyun QIU. An electromagnetic semi-active dynamic vibration absorber for thin-walled workpiece vibration suppression in mirror milling. Applied Mathematics and Mechanics (English Edition), 2024, 45(8): 1315-1334.

TrendMD

Figures/Tables 21

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Table 1

Fig. 9

Fig. 10

Fig. 11

Fig. 12

Fig. 13

Fig. 14

Fig. 15

Table 2

Fig. 16

Fig. 17

Fig. 18

Fig. 19

References 28

1	DEL SOL, I., RIVERO, A., DE LACALLE, L. N. L., and GAMEZ, A. J. Thin-wall machining of light alloys: a review of models and industrial approaches. Materials, 12 (12), 2012 (2019)
2	DONG, H. Q., JI, Y. L., WANG, X. Z., and BI, Q. Z. Stability analysis of thin-walled parts end milling considering cutting depth regeneration effect. International Journal of Advanced Manufacturing Technology, 113 (11-12), 3319- 3328 (2021)
3	DU, J. A., and LONG, X. H. Chatter suppression for milling of thin-walled workpieces based on active modal control. Journal of Manufacturing Processes, 84, 1042- 1053 (2022)
4	WAN, M., DANG, X. B., ZHANG, W. H., and YANG, Y. Chatter suppression in the milling process of the weakly-rigid workpiece through a moving fixture. Journal of Materials Processing Technology, 299, 117293 (2022)
5	MAHMUD, A., MAYER, J. R. R., and BARON, L. Determining the minimum clamping force by cutting force simulation in aerospace fuselage pocket machining. International Journal of Advanced Manufacturing Technology, 80 (9-12), 1751- 1758 (2015)
6	BAO, Y., WANG, B., HE, Z. X., KANG, R. K., and GUO, J. Recent progress in flexible supporting technology for aerospace thin-walled parts: a review. Chinese Journal of Aeronautics, 35 (3), 10- 26 (2022)
7	WANG, S. Q., HE, C. L., LI, J. G., and WANG, J. Vibration-free surface finish in the milling of a thin-walled cavity part using a corn starch suspension. Journal of Materials Processing Technology, 290, 116980 (2021)
8	SHENG, X. J., and ZHANG, X. Fuzzy adaptive hybrid impedance control for mirror milling system. Mechatronics, 53, 20- 27 (2018)
9	ZHANG, S., BI, Q., JI, Y., and WANG, Y. Real-time thickness compensation in mirror milling based on modified Smith predictor and disturbance observer. International Journal of Machine Tools & Manufacture, 144, 103427 (2019)
10	TIAN, Y., XIAO, J. L., LIU, S. J., MA, S. J., LIU, H. T., and HUANG, T. Vibration and deformation suppression in mirror milling of thin-walled workpiece through a magnetic follow-up support fixture. Journal of Manufacturing Processes, 99, 168- 183 (2023)
11	LIU, S. J., XIAO, J. L., TIAN, Y., MA, S. J., LIU, H. T., and HUANG, T. Chatter-free and high-quality end milling for thin-walled workpieces through a follow-up support technology. Journal of Materials Processing Technology, 312, 117857 (2023)
12	DENG, H. X., and GONG, X. L. Adaptive tuned vibration absorber based on magnetorheological elastomer. Journal of Intelligent Material Systems and Structures, 18 (12), 1205- 1210 (2007)
13	SUN, S. S., CHEN, Y., YANG, J., TIAN, T. F., DENG, H. X., LI, W. H., DU, H., and ALICI, G. The development of an adaptive tuned magnetorheological elastomer absorber working in squeeze mode. Smart Materials and Structures, 23 (7), 075009 (2014)
14	YUAN, L., SUN, S., PAN, Z., DING, D., GIENKE, O., and LI, W. Mode coupling chatter suppression for robotic machining using semi-active magnetorheological elastomers absorber. Mechanical Systems and Signal Processing, 117, 221- 237 (2019)
15	KWAK, M. K., YANG, D. H., and SHIN, J. H. Active vibration control of structures using a semi-active dynamic absorber. Noise Control Engineering Journal, 63 (3), 287- 299 (2015)
16	MCDAID, A. J., and MACE, B. R. A self-tuning electromagnetic vibration absorber with adaptive shunt electronics. Smart Materials and Structures, 22 (10), 105013 (2013)
17	CHANG, Y., ZHOU, J., WANG, K., and XU, D. Theoretical and experimental investigations on semi-active quasi-zero-stiffness dynamic vibration absorber. International Journal of Mechanical Sciences, 214, 106892 (2022)
18	MENG, K., GU, Y., LIU, Y., and MA, T. Transmissibility characteristics of semi-active vibration isolator based on controllable electro-magnetic negative stiffness. Journal of Vibration and Shock, 41 (7), 228- 234 (2022)
19	WANG, Q., ZHOU, J., WANG, K., LIN, Q., XU, D., and WEN, G. A compact quasi-zero-stiffness device for vibration suppression and energy harvesting. International Journal of Mechanical Sciences, 250, 108284 (2023)
20	WANG, Q., ZHOU, J., WANG, K., GAO, J., LIN, Q., CHANG, Y., XU, D., and WEN, G. Dual-function quasi-zero-stiffness dynamic vibration absorber: low-frequency vibration mitigation and energy harvesting. Applied Mathematical Modelling, 116, 636- 654 (2023)
21	MOFIDIAN, S. M. M., and BARDAWEEL, H. A dual-purpose vibration isolator energy harvester: experiment and model. Mechanical Systems and Signal Processing, 118, 360- 376 (2019)
22	MOFIDIAN, S. M. M., and BARDAWEEL, H. Theoretical study and experimental identification of elastic-magnetic vibration isolation system. Journal of Intelligent Material Systems and Structures, 29 (18), 3550- 3561 (2018)
23	CAI, Q., and ZHU, S. The nexus between vibration-based energy harvesting and structural vibration control: a comprehensive review. Renewable and Sustainable Energy Reviews, 155, 111920 (2022)
24	XIE, L., LI, J., LI, X., HUANG, L., and CAI, S. Damping-tunable energy-harvesting vehicle damper with multiple controlled generators: design, modeling and experiments. Mechanical Systems and Signal Processing, 99, 859- 872 (2018)
25	YAN, B., WANG, K., KANG, C. X., ZHANG, X. N., and WU, C. Y. Self-sensing electromagnetic transducer for vibration control of space antenna reflector. IEEE/ASME Transactions on Mechatronics, 22 (5), 1944- 1951 (2017)
26	GRIFFITHS, D. J. Introduction to Electrodynamics, Pearson Education, New York (2014)
27	NGUYEN, H. T., DENTCHO, G., and HAMZEH, B. Mono-stable and bi-stable magnetic spring based vibration energy harvesting systems subject to harmonic excitation: dynamic modeling and experimental verification. Mechanical Systems and Signal Processing, 134, 106361 (2019)
28	NGUYEN, H. T., GENOV, D. A., and BARDAWEEL, H. Vibration energy harvesting using magnetic spring based nonlinear oscillators: design strategies and insights. Applied Energy, 269, 115102 (2020)

[1]	Zeyu CHAI, J. T. HAN, Xuyuan SONG, Jian ZANG, Yewei ZHANG, Zhen ZHANG. Theoretical and experimental investigations on an X-shaped vibration isolator with active controlled variable stiffness [J]. Applied Mathematics and Mechanics (English Edition), 2024, 45(8): 1371-1386.
[2]	Long ZHAO, Zeqi LU, Hu DING, Liqun CHEN. A viscoelastic metamaterial beam for integrated vibration isolation and energy harvesting [J]. Applied Mathematics and Mechanics (English Edition), 2024, 45(7): 1243-1260.
[3]	Dongxing CAO, Junru WANG, Xiangying GUO, S. K. LAI, Yongjun SHEN. Recent advancement of flow-induced piezoelectric vibration energy harvesting techniques: principles, structures, and nonlinear designs [J]. Applied Mathematics and Mechanics (English Edition), 2022, 43(7): 959-978.
[4]	Xiangjian DUAN, Dongxing CAO, Xiaoguang LI, Yongjun SHEN. Design and dynamic analysis of integrated architecture for vibration energy harvesting including piezoelectric frame and mechanical amplifier [J]. Applied Mathematics and Mechanics (English Edition), 2021, 42(6): 755-770.
[5]	Jin ZENG, Hui MA, Kun YU, Zhitao XU, Bangchun WEN. Coupled flapwise-chordwise-axial-torsional dynamic responses of rotating pre-twisted and inclined cantilever beams subject to the base excitation [J]. Applied Mathematics and Mechanics (English Edition), 2019, 40(8): 1053-1082.
[6]	Qianli ZHAO, Zhili SUN. In-plane forced vibration of curved pipe conveying fluid by Green function method [J]. Applied Mathematics and Mechanics (English Edition), 2017, 38(10): 1397-1414.
[7]	Zhiyong AI, Lihua WANG. Layer-element analysis of multilayered saturated soils subject to axisymmetric vertical time-harmonic excitation [J]. Applied Mathematics and Mechanics (English Edition), 2017, 38(9): 1295-1312.
[8]	DING Bo-Yang;DANG Gai-Hong;YUAN Jin-Hua. Lamb’s integral formulas of two-phase saturated medium for soil dynamic with drainage [J]. Applied Mathematics and Mechanics (English Edition), 2010, 31(09): 1113-1124.
[9]	ZHANG Zhi-liang;CHENG Chang-jun. Forced vibration and special effects of revolution shells in turning point range [J]. Applied Mathematics and Mechanics (English Edition), 2007, 28(7): 861-872 .
[10]	HU Ji-yun;YIN Xue-gang;YU Cui-ping. ELECTROMECHANICAL COUPLING MODEL AND ANALYSIS OF TRANSIENT BEHAVIOR FOR INERTIAL RECIPROCATION MACHINES [J]. Applied Mathematics and Mechanics (English Edition), 2005, 26(11): 1499-1505 .
[11]	Chao FU, Kuan LU, Y. D. XU, Yongfeng YANG, F. S. GU, Yushu CHEN. Dynamic analysis of geared transmission system for wind turbines with mixed aleatory and epistemic uncertainties [J]. Applied Mathematics and Mechanics (English Edition), 2022, 43(2): 275-294.
[12]	Jingming FAN, Bo CHEN, Yinghui LI. Closed-form steady-state solutions for forced vibration of second-order axially moving systems [J]. Applied Mathematics and Mechanics (English Edition), 2023, 44(10): 1701-1720.
[13]	Zhiyuan WU, Linchuan ZHAO, Han YAN, Ge YAN, Ao CHEN, Wenming ZHANG. Multi-blade rubbing characteristics of the shaft-disk-blade-casing system with large rotation [J]. Applied Mathematics and Mechanics (English Edition), 2024, 45(1): 111-136.