Design and Characterization of a Magnetorheological Damper for Vibration Mitigation during Milling of Thin Components
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Design and Characterization of a Magnetorheological Damper for Vibration Mitigation during Milling of Thin Components S. Puma-Araujo1, D. Olvera-Trejo2, A. Elías-Zuñiga2, O. Martínez-Romero2, C.A. Rodríguez2 1 Department of Mechanical Engineering, Tecnológico de Monterrey, ITESM, Eugenio Garza Sada 2501 Sur, Monterrey 64849, Nuevo León, México. 2 School of Engineering and Science, Tecnológico de Monterrey, ITESM, Eugenio Garza Sada 2501 Sur, Monterrey 64849, Nuevo León, México. ABSTRACT The aerospace and automotive industries demand the development of new manufacturing processes. The productivity during machining of very flexible aerospace and automotive aluminum components is limited for self-excited vibrations. New solutions are needed to suppress vibrations that affect the accuracy and quality of the machined surfaces. Rejection of one piece implies an increase in the manufacturing cost and time. This paper is focused on the design, manufacturing and characterization of a magnetorheological damper. The damper was attached to a thin-floored component and a magnetic field was controlled in order to modify the damping behavior of the system. The dynamics of the machining process was developed by considering a three-degree-of-freedom model. This study was experimentally validated with a bull-nose end milling tool to manufacture monolithic parts with thin wall and thin floor. Experimental tests and characterization of the magnetorheological damper permitted to improve the surface finish and productivity during the machining of thin-floored components. A further aim of this paper was to develop a rheological damper by using magnetorheological fluids (MR) to change the thin floor rigidity with voltage. The stability of the milling process was also analytically described considering one, two or three degrees of freedom, using a mathematical integration model based on the Enhanced Multistage Homotopy Perturbation Method (EMHPM). INTRODUCTION Civilian aircraft manufacturers are committed to achieve two important goals in a short time. The first one is to reduce the operating costs per passenger to offset the high oil prices, resulting in a more attractive offer for the airlines. The other one has an ecological scope, aiming to contribute to the improvement of the environment by reducing pollution and by accomplishing environmental protection laws, which turn more severe nearly on a daily basis. Due to all these factors, major companies, such as Airbus and Boeing, have had to restructure their designs, working on the dimensions of the aircrafts and in the materials used for their fabrication. In order to improve the efficiency of fuel consumption, Boeing builds the 787 Dreamliner with almost 50% of its weight in composite materials at the expense of aluminum, which constitutes only 20% of the aircraft’s weight (see Fig. 1). The bet of Boeing in composites has been so strong, that it is the first company to have built an aircraft fuselage entirely made of polymers reinforced with carbon fibers.
Figure 1. (a) Materials and
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