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<p>It is challenging to suppress chatter in face-hobbing gear machining, because it involves very complex spatial kinematic and time-varying dynamic characteristics compared to other machining techniques. This study presents a novel reconfigurable distributed-mass-damping dynamic vibration absorber (DMDVA) with excellent robustness for chatter suppression in face-hobbing gear machining. Unlike traditional tuned mass dampers (TMDs) with fixed setups, the proposed DMDVA introduces three key innovations: (1) a modular design that allows for adjustable mass distribution and damping topology through spatial reconfiguration of functional units; (2) a frequency-adaptive mechanism tailored for the changing dynamics in hypoid gear cutting; and (3) an integrated tuning framework based on differential evolution that considers machine-tool-workpiece interactions. Systematic comparison of compliance characteristics across multiple layouts shows that the optimal DMDVA configuration achieves a 42% wider adequate bandwidth and 68% higher damping efficiency than conventional TMDs. Experimental and numerical results on gear cutting machines demonstrate significant performance improvements: an 88.92% reduction in chatter amplitude (compared to 56.41% with TMD), and tooth flank normal deviation decreased from 1.7190 to 1.5164 μm on convex surfaces and from 0.5757 to 0.4722 μm on concave surfaces. The reconfigurable topology allows dynamic adjustment of natural frequency over a broad range, effectively addressing variations in process parameters during complex tooth flank machining. These contributions provide a systematic and adaptive approach for precise vibration control in multi-axis gear manufacturing systems.</p>

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A novel robust distributed mass-damping vibration absorber for spiral bevel gear face-hobbing chatter mitigation

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Jianwu Yu,
  • Kaifeng Huang,
  • Jun Qian,
  • Zhentao Shang,
  • Chunming Fu,
  • Min Tan

摘要

It is challenging to suppress chatter in face-hobbing gear machining, because it involves very complex spatial kinematic and time-varying dynamic characteristics compared to other machining techniques. This study presents a novel reconfigurable distributed-mass-damping dynamic vibration absorber (DMDVA) with excellent robustness for chatter suppression in face-hobbing gear machining. Unlike traditional tuned mass dampers (TMDs) with fixed setups, the proposed DMDVA introduces three key innovations: (1) a modular design that allows for adjustable mass distribution and damping topology through spatial reconfiguration of functional units; (2) a frequency-adaptive mechanism tailored for the changing dynamics in hypoid gear cutting; and (3) an integrated tuning framework based on differential evolution that considers machine-tool-workpiece interactions. Systematic comparison of compliance characteristics across multiple layouts shows that the optimal DMDVA configuration achieves a 42% wider adequate bandwidth and 68% higher damping efficiency than conventional TMDs. Experimental and numerical results on gear cutting machines demonstrate significant performance improvements: an 88.92% reduction in chatter amplitude (compared to 56.41% with TMD), and tooth flank normal deviation decreased from 1.7190 to 1.5164 μm on convex surfaces and from 0.5757 to 0.4722 μm on concave surfaces. The reconfigurable topology allows dynamic adjustment of natural frequency over a broad range, effectively addressing variations in process parameters during complex tooth flank machining. These contributions provide a systematic and adaptive approach for precise vibration control in multi-axis gear manufacturing systems.