Milling tools with a large length–diameter ratio are widely applied in machining structural features with deep depth. However, their high dynamic flexibility gives rise to chatter vibrations, which results in poor surface finish, reduced productivity, and even tool damage. With a passive tuned mass damper (TMD) embedded inside the arbor, a large length–diameter ratio milling tool with chatter-resistance ability was developed. By modeling the milling tool as a continuous beam, the tool-tip frequency response function (FRF) of the milling tool with TMD was derived using receptance coupling substructure analysis (RCSA), and the gyroscopic effect of the rotating tool was incorporated. The TMD parameters were optimized numerically with the consideration of mounting position based on the maximum cutting stability criterion, followed by the simulation of the effectiveness of the optimized and detuned TMD. With the tool-tip FRF obtained, the chatter stability of the milling process was predicted. Tap tests showed that the TMD was able to increase the minimum real part of the FRF by 79.3%. The stability lobe diagram (SLD) was predicted, and the minimum critical depth of cut in milling operations was enhanced from 0.10 to 0.46 mm.

The multi-degrees-of-freedom (MDOF) tuned mass damper (TMD) has proven its ability to suppress multiple modes of interest, and it possesses less mounting space than multiple single degree-of-freedom TMDs of equal damping mass. However, it is challenging to implement the exact design of MDOF TMDs having expected vibration modes. The conceptual design of MDOF TMD containing visualized DOFs is first presented by the graphical approach, and the visualization of the quantitative relationship between the freedoms and constraints of TMD is attained. Then, dynamics modeling is analytically formulated by incorporating experimental data, and optimization of MDOF TMD considering background modes is performed. Two scenarios of MDOF TMD (i.e., 2DOFs TMD and 3DOFs TMD) are simulated. Vibration suppression of single dominant mode and multiple modes are achieved, corresponding to the case when the primary structure is subjected to wide and narrow band harmonic excitations, respectively. Afterward, a TMD with one rotational and two translational (1R2 T) DOFs is designed by embodying the geometric constraint patterns by flexible beams, and changeable elastic elements are incorporated. Experiments show that the first, second, and third bending modes of the cantilever beam are suppressed by 80.0%, 67.5%, and 61.2%, respectively, by the 3DOFs TMD for multiple modes suppression.

A piezoelectric vibration sensing system (PVSS) was devised in this study and employed for the purpose of vibration sensing in machining. The system comprises three primary components, wherein the sensor is utilized for the collection and conversion of energy, subsequently transmitting it to the data acquisition card (DAC) via a low-noise cable. The crux of the entire system lies in the upper computer-based control application, which facilitates the transmission of instructions to the DAC for data acquisition and transmission. The integration of Wi-Fi data transfer capability between the DAC and the computer serves to eliminate the principal issue associated with employing the sensor as a voltage source. The sensitivity of the designed device was calibrated utilizing commercial accelerometers, while an aluminum workpiece was fabricated to conduct vibration and machining tests in order to verify the performance of the PVSS. The shaker excitation experiment yielded a peak voltage of 0.05 mV, thereby substantiating that the PVSS can more accurately discern the natural frequency of the workpiece below 5000 Hz compared to commercial accelerometers. The experiments verify that the devised PVSS can precisely measure vibrations during the milling process, and can be implemented for the purpose of detecting machining stability.

Vibration control constitutes a critical consideration in structural design, as excessive oscillations may precipitate fatigue damage, operational instability, and catastrophic failures. Dynamic vibration absorbers (DVAs), serving as passive control devices, demonstrate remarkable efficacy in mitigating structural vibrations across engineering applications. This study systematically investigates the design of DVAs for vibration suppression of a cantilevered plate through integrated theoretical modeling, parameter optimization, structural implementation, and experimental validation. Key methodologies encompass receptance coupling substructure analysis (RCSA) for system dynamics characterization and H∞ optimization for absorber parameter identification. Experimental results reveal 74.2–85.7% vibration amplitude reduction in target mode, validating the proposed design framework. Challenges pertaining to boundary condition uncertainties and manufacturing tolerances are critically discussed, providing insights for practical implementations.