Cutting conditions dependent adjustment of dynamic responses for slender tools in internal turning with a flexible vibration suppression device

A series of challenges confront the slender tool during the internal turning of difficult-to-machine materials, including issues such as chatter, poor surface quality and cutting tool failure, all of which significantly impacting machining quality and efficiency. Thus, this paper proposes a flexible vibration suppression device for the slender turning tool. Different components are designed to enhance damping capacity or adjust tool frequency, respectively. An accurate dynamical model is developed for the slender internal turning tool equipped with the vibration suppression device. In the contact region between the tool and workpiece, the generated dynamic force is modeled by comprehensively considering the material properties and tool geometry. In the contact region between the tool and clamping device, the effect of flexible boundary constraints is first taken into account in predicting tool dynamics. Additionally, an inversion method, considering the uniqueness of the solution, is proposed to accurately identify the boundary condition. Based on this, a cutting conditions dependent adjustment strategy is proposed optimize tool dynamics. Under the premise of accurately predicting the tool dynamics and stability limit, the tool dynamics are adjusted to continuously adapt to the pre-selected tool geometry and cutting parameters through the design of the tuned damper. A series of internal turning tests are conducted on difficult-to-machine materials. The experimental results demonstrate the effectiveness of the flexible device and the corresponding adjustment strategy in avoiding tool chatter and improving surface quality.