Design and FEM simulation of damped milling cutter

Abstract

Milling cutter with large length-diameter ratio is usually used in machining complex aerospace parts with deep pockets and thin ribs. Large overhang causes stiffness reduction of the cutting tool, which is a significant factor leading to machining chatter. Damped milling cutter can effectively suppress the vibration. Three structural designs of damped cutter are proposed, and modal analysis and harmonious analysis are performed by ANSYS. Simulation results show that the milling cutter embedded with two degree-of-freedom passive damper exhibits the best vibration suppression and the magnitude of frequency response is reduced by 63.7%, which therefore enhances the machining stability.