Design and optimization of an integrated spindle tool system using semi active control for an end-mill

Chatter often leads to an increase in production expenses and a decrease in productivity. Evidently, the presence of chatter reduces the pace at which material is removed, thereby decreasing the workload and productivity of the operation. Active structural control techniques are the most promising routes for improving the dynamic stability of cutting processes. In the current study, finite element modeling with Timoshenko beam theory with rotary and shear deformation is utilized for modeling of integrated spindle tool system. A semi-active approach is developed with the aim of reducing the chatter vibration levels and in turn to maximize the average stable depth of cut in an end milling process. Implementation of the semi-active approach led to a significant 51% reduction in chatter vibrations, resulting in smoother machining operations. The stability boundaries are empirically confirmed by machining tests conducted on Al6061-alloy workpieces. To ensure the stability of the cutting process vibration levels and optical microscope images are considered to detect the chatter marks at different possible combinations of the machining conditions. Furthermore, a meta-heuristic approach such as particle swarm optimization is developed for the dynamic model to ensure the location of vibration absorber and the corresponding stability lobes are arrived. Optimization using particle swarm optimization increased the average stable depth of cut by a factor of 3.7, enhancing productivity and reducing the likelihood of chatter-induced disruptions. These findings demonstrate the efficacy of the proposed methodology in enhancing machine stability and performance, offering practical benefits for manufacturing industries.