Traditional boring bars are generally made up of isotropic metallic materials and exhibit extremely poor chatter suppression ability. For enhancing the chatter stability, using anisotropic composite materials in the preparation of boring bars proves to be an effective method so as to enhance the boring bar’s natural frequency and damping. Additionally, the addition of constrained layer damping (CLD) technology on the composite boring bar can further improve the damping performance. This study aims to develop a theoretical analysis model for the prediction of the chatter stability of the CLD composite boring bar and explore the effectiveness and practicability of the CLD technology in suppressing the chatter of composite boring bar. Based on Euler–Bernoulli beam theory and the complex stiffness method of CLD, the structural dynamic model of the CLD composite boring bar was derived, and some structural parameters of the bar mainly including the ply angle of the composite material, the thicknesses of both damping layer, and constrained layer were also optimized. By combining the linear model of cutting force with a regenerative delay effect and the established dynamic model, the chatter analysis model of the CLD composite boring bar was constructed and the lobe diagram of the chatter stability of the cutting system was plotted by means of frequency domain method. The effects of the ply angle of the composite boring bar, the thicknesses of damping layer, and constrained layer on the chatter stability were examined. By performing time integral of the delay equation of motion, the time-domain response curves of the cutting system are obtained. The chatter stability prediction results based on the lobe diagram fit well with the prediction results on the basis of dynamic stiffness calculation and time-domain numerical integral results.

Using the cutter bar made with composite rather than metal in high rotating speed milling or boring operations is a new attempt for suppressing chatter of the cutting system. This is because composite material has much higher specific stiffness and damping as well as dynamic stiffness compared to metal. But, for a rotating composite cutter bar, larger internal damping (or rotational damping) occurs, and such damping may cause the rotor instability in the perspective of rotor dynamics. On the other hand, the effect of internal damping of a rotating composite cutter bar on the chatter stability in high speed cutting process is also an important issue worthy of concern. In this paper, a new dynamic model of the cutting system with a rotating composite cutter bar is presented. The cutter bar is modelled as a rotating, cantilever, tapered, composite Euler–Bernoulli shaft, subjected to a regenerative cutting force. Modal damping loss factors are described based on the viscoelastic constitutive relation of composite combined with an energy approach. The governing equations of the system are obtained by employing Hamilton principle. Galerkin method is used to discretize the partial differential equations of motion. The frequency-domain solution of stability proposed by Altintas and Budak [14] is extended and used to predict the chatter stability of the cutting system. The results reveal the inherent relationship between internal damping instability and cutting chatter. The effects of the geometry parameters of the cutter bar, ply angle, stacking sequences, and internal and external damping are examined.

The free vibration and damping characteristics of rotating shaft with passive constrained layer damping (CLD) are studied. The shaft is made of fiber reinforced composite materials. A composite beam theory taking into account transverse shear deformation is employed to model the composite shaft and constraining layer. The equations of motion of composite rotating shaft with CLD are derived by using Hamilton’s principle. The general Galerkin method is applied to obtain the approximate solution of the rotating CLD composite shaft. Numerical results for the rotating CLD composite shaft with simply supported boundary condition are presented; the effects of thickness of constraining layer and viscoelastic damping layers, lamination angle, and rotating speed on the natural frequencies and modal dampings are discussed.

In this paper, the nonlinear dynamic analysis of the cutting process of composite cutting tool is performed. The cutting tool is simplified to a nonplanar bending rotating shaft. The higher-order bending deformation, structural damping, and gyroscopic effect of cutting tool are considered. It is assumed that cutting tool is subjected to a regenerative two-dimensional cutting force containing the first and second harmonic components. Based on the Hamilton principle, the motion equation of nonlinear chatter of the cutting system is derived. The nonlinear ordinary differential equations in the generalized coordinates are obtained by Galerkin method. In order to analyze the nonlinear dynamic response of cutting process, the multiscale method is used to derive the analytical approximate solution of the forced response for the cutting system under periodic cutting forces. In the forced response analysis, four cases including primary resonance and superharmonic resonance, i.e., , , , and , are considered. The influences of ratio of length to diameter, structural damping, cutting force, and ply angle on primary resonance and superharmonic resonance are investigated. The results show that nonlinearity due to higher-order bending deformation significantly affects the dynamic behavior of the milling process and that the effective nonlinearity of the cutting system is of hard type. Multivalued resonance curves and jump phenomenon are presented. The influences of various factors, such as ratio of length to diameter, ply angle, structural damping, cutting force, and rotating speed, are thoroughly discussed.

Traditional milling cutter bars are generally made up of metals and exhibit poor capacity of chatter suppression. This study proposes an anisotropic composites tapered cutter bar for increasing natural frequency and damping and finally achieves the goal of enhancing chatter stability. Based on Hamilton principle and Euler–Bernoulli beam theory, the partial differential motion equations of the cutting system with a 3D rotating tapered composite cutter bar are established. Next, using the Galerkin method, the equations of motion are discretized so as to derive ordinary differential equations. In the model, damping modeling of the composite cutter bar is achieved theoretically by using damping dissipation constitutive relations for viscoelastic composites. Moreover, by introducing the rotating effect of the 3D cutter bar in the 2-DOF analytical model of stability analysis first proposed for a fixed-type cutter bar, an improved prediction model is developed and used to solve the stability lobes of the cutting system in the frequency domain analytically. Furthermore, the influences of the gyroscopic effect, material, ply angle, stacking sequence, and taper ratio on chatter stability are also discussed.

This paper studies the chatter stability of composite cutter bar milling system in rotating coordinate frame. The main contribution of this paper is establishing a continuous distributed chatter analysis model for a composite cutter bar milling system in rotating coordinate frame. The stability of the milling system with a rotary symmetric dynamic cutter bar is predicted using the semi‐discrete time domain method. The effects such as internal damping, external damping, and symmetrical and asymmetric laminates on the stability of the milling system were analysed, and the results were compared between rotating and fixed coordinate frames. The results are consistent for symmetrical cutter bars in both the rotating and fixed coordinate frames. A new chatter instability zone appears at high rotating speeds due to the material internal damping of the rotating composite cutter bar.