Evaluation of complaint damper for assessing its effectiveness and efficiency through the utilization of topology optimization

The term 'chatter' is related to the undesirable vibration produced in any equipment under dynamic operating conditions. It has a wide range of negative consequences for both the machine and the components it produces. Vibrations in the process of machining must be minimized as much as feasible. Dampers serve an important function in mitigating the impacts of chatter during machining. Dampers have traditionally been used to support machines and reduce clatter. Dampers are currently made up of numerous pieces that are mechanically joined together to perform the needed task of reducing chatter. To reduce the number of components and mechanical assembly, we use a complaint mechanism that transmits and absorb force, motion, and so on in a single monolithic structure. This paper presents a unique method to construct dampers utilizing a complaint system. A design was created implementing building pieces in a structure that has been topology optimized. The complaint damper was created using Fused Deposition Modeling (FDM). The complaint damper was employed in place of the rubber damper to evaluate performance. The experiments were carried out on a 3D printer (Fractal Twin Dragon) under various operating circumstances. During the experiment, a 1.75 mm diameter PLA spool was used as the feed. The machine attributes were taken into account. The complaint damper was located at the bottom of the machine's leg. The vibrometer VB-820HA contact type was also mounted to the machine leg and measured response that include velocity, acceleration, displacement, and frequency. The acceleration & frequency profile clearly suggest a larger magnitude when the complaint damper is used. When compared to conventional solid damping, The initial runs are at lower federate of 0.6 mm/min shows nearly identical velocity readings between the two dampers. Rubber damping resulted in a maximum displacement of 0.55 mm. The displacement created by the suggested damper is insignificant. even at higher frequencies. The compliant damper has increased this frequency to a whole new level above 1000 Hz. Higher chatter effects will be produced only at high-speed operations. At that condition, the proposed complaint dampers show drastic reduction in surface roughness by eliminating the damages caused by peak vibrations.