Design and development of a milling tool-holder with differentiated damping using additive manufacturing

• Grant number: 22/15409-0
• Support Opportunities: Scholarships abroad - Research
• Start date: September 01, 2023
• End date: August 31, 2024
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Armando Ítalo Sette Antonialli
• Grantee: Armando Ítalo Sette Antonialli
• Host Investigator: Giovanni Totis
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil
• Institution abroad: Università degli Studi di Udine, Italy

Abstract

The dynamic evaluation of machining processes, especially those related to interrupted cutting, as milling, has been the very first motivation for several research groups on manufacturing all around the world. Lots of efforts has been focused on identifying conditions that may reduce or suppress self-excited vibration, also called chatter, as they directly impair tool life, surface integrity of the machined parts, and consequently the productivity of those operations. Some of them may be highlighted: construction of new algorithms for prediction of the stability limits from experimental data, development of special tools with geometric features to avoid resonance conditions and adoption of technologies to the improvement of damping capacity of the system including machine, tool, fixture and workpiece. In this project, topology optimization technique is proposed to the formulation of a tool holder for the mitigation of chatter on milling. Due to the specificity regarding geometrical features, it will be produced by additive manufacturing through selective laser melting. Finally, this product provided differentiated damping will be tested under several cutting conditions along with vibration monitoring in order to validate the project. (AU)