ARTICLE IN PRESS

International Journal of Machine Tools & Manufacture 48 (2008) 10361053

www.elsevier.com/locate/ijmactool

Design and implementation of tuned viscoelastic dampers

for vibration control in milling
Amir Rashida,, Cornel Mihai Nicolescub
a

System 3R International AB, Sorterargatan 1, 16250 Vallingby, Sweden

Department of Production Engineering, The Royal Institute of Technology, Brinellvagen 68, 10044 Stockholm, Sweden

Received 27 July 2007; received in revised form 19 December 2007; accepted 21 December 2007
Available online 15 January 2008

Abstract
Passive means of vibration attenuation have been employed successfully and efciently in machining systems such as turning and
milling. Traditional approach to controlling vibration in a milling system is to develop control mechanisms for cutting tools or machine
spindles. However, due to the nature of milling operations where the cutting tools rotate at high speed, the passive vibration control
methods nd very limited application with the traditional approach. In order to utilise the potential of the passive vibration control
methodology in milling applications, the milling operation should be viewed as a system comprising an elastic structure and operation
parameters. Dynamics of this closed-loop system should improve with improvement in dynamics of any of the system components,
especially within the elastic structure that comprises the cutting tool, the machine tool, the workholding system and the workpiece.
Although the level of improvement will vary depending on which component of the elastic chain is targeted for this purpose. This paper
presents the development and testing of tuned viscoelastic dampers (TVDs) for vibration control through their application on a
workpiece in milling operations. This work targets workpiece held on a palletised workholding system for the control of unwanted
vibration and thus deviates from the traditional approach where cutting tool and/or machine spindles are targeted for vibration control
strategies. Palletised workholding systems, due to their compact design, offer an opportunity to design passive damping mechanisms that
are easier to implement in the case of a milling system. The TVD developed through this research is based on a commercially available
viscoelastic damping polymer. Advantage of such materials is their high damping performance over a wide range of excitation
frequencies. The TVD design process has used a unique combination of analytical modelling with experimental FRF data. Modal impact
testing showed that the application of the TVD reduced the amplitude of vibration acceleration by 20 dB for the target mode. Since the
target mode corresponded to torsional vibration, the TVD was effective in two planar coordinates, i.e. X and Y. In addition, the TVD
also signicantly reduced the amplitude of a vibration mode far from the mode it was designed for. The system has been tested
experimentally to demonstrate signicant reduction in vibration amplitudes during a milling process. The milling tests with different
combinations of cutting parameters show that multi-TVD approach is always valid regardless of the parameters being used. The only
requirement for TVDs to function effectively is that the natural frequency of the system, for which the TVDs are designed, is excited
during the milling process.
r 2008 Elsevier Ltd. All rights reserved.
Keywords: Passive vibration control; Palletised workholding; Milling; Tuned viscoelastic damper (TVD)

1. Introduction
Vibrations are an inextricable part of machining processes
and modern machine shops are well aware of their
detrimental effects. Process vibrations should be minimised
Corresponding author. Tel.: +46 8 6202166; fax: +46 8 384516.

E-mail address: amir.rashid@system3r.se (A. Rashid).

0890-6955/$ - see front matter r 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2007.12.013

in order to improve accuracy and surface nish of machined

components. Phenomenon of chatter which is associated
with unstable vibrations in machining may cause accelerated
wear and possibly breakage of both the cutting tool and
machine tool. Furthermore, it is also a major factor in
limiting metal removal rates in high-speed machining [1].
Considerable research efforts have been put into
controlling or reducing the extent of this damaging

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A. Rashid, C.M. Nicolescu / International Journal of Machine Tools & Manufacture 48 (2008) 10361053

Nomenclature
VD
f(t)
F
F1,
FD
k
k*
K
m
M

tuned viscoelastic damper

force exerted by TVD as function of time
magnitude of steady-state force applied to main
structure
F2, y magnitude of steady-state forces applied to
three-DOF system masses M1, M2, y
magnitude of opposing force exerted by TVD
stiffness of elastic spring of TVD
stiffness of viscoelastic spring of TVD
stiffness of elastic spring of main structure
TVD mass
main structure mass

vibration in machining systems by using various vibration control or attenuation methods. These methods
include both process parameter control to avoid chatter
conditions and structural modications to improve
dynamic stiffness of the elastic structure of machining
systems [28].
One of the structural modication methods to attenuate
unwanted vibration in machining systems is through
addition of auxiliary systems known as tuned damping
devices. Such damping devices include a single degree of
freedom (SDOF) system consisting of a mass on a linear
spring with viscous damping, a mass on a viscoelastic
spring, a tuned viscoelastic link joining different elements
of a complex structure and a viscoelastically damped
resonant beam [9,10]. All these devices add damping into
the structure through energy dissipation and therefore are
differentiated from dynamic absorbers that are undamped tuned resonators working as energy-transfer
devices.1 The tuned dampers dissipate energy depending
on the local displacements in a structure in comparison to
layered damping treatments where the efciency of
damping treatments depends on surface strains. For a
tuned damper to be effective, there are two essential
prerequisites [11]:




Damper should be located at a point of high displacement, such as an anti-node.

The structure should have a single resonance or a group
of resonances with similar strain energies.

Tuned dampers can also be designed to be effective over

a broad range of frequencies, if the structural resonances
are well separated.
1
Although a tuned damper should be differentiated from a dynamic
vibration absorber (DVA), the term DVA has been frequently used for
tuned viscous dampers in the reviewed research, and for the sake of
originality, this term has been maintained while summarising this research
here. However, in this paper, the term tuned viscoelastic damper (TVD) is
used for the tuned damper as the design is based on viscoelastic damping
model.

1037

x(t)
x0
X(t)
X0

vibration of TVD as function of time

magnitude of steady-state vibration of TVD
vibration of main structure as function of time
magnitude of steady-state vibration of main
structure
X1, X2, y magnitude of steady-state vibration of threeDOF system masses M1, M2, y
a11
transfer receptance measured on mass M1 of
the system without TVD
aD
transfer
receptance measured on mass M1 of
11
the system with TVD
Z
loss factor
o
frequency of excitation
on
natural frequency

Structural modication devices such as tuned dampers

have been used effectively in turning and boring operations
by integrating them in the cutting tools: a typical approach
for machining processes where the tools are always
stationary. However, due to high-speed rotation of the
cutting tool in case of milling, implementation of the tuned
dampers is not possible through the conventional approach.
Regarding the implementation of tuned dampers for
vibration attenuation in the eld of machining, most of the
published research refers to tuned dampers applied to
cantilever type tools such as boring bars. The objective has
been to improve dynamic stability of such tools and thus
improve accuracy, surface nish and tool life. Improved
dynamic stability also helps increasing the limits of stable
machining regimes in terms of both cutting parameters and
geometric design, for example, length-to-diameter (L/D)
ratio in case of boring bars.
The work in Ref. [12] reports use of tuneable dynamic
vibration absorber (DVA) in a boring bar that improves
the L/D ratio reaching a value as high as 15 in comparison
to previously reported highest of 9.5. The DVA in this case
is modelled as a mass residing on a linear spring with
viscous damping. Performance of the DVA is studied
analytically and validated by cutting tests. Proposed design
has the exibility of tuning the system to a range of
excitation frequencies. This is achieved by changing
effective stiffness of the DVA inertial system suspended
on rubber O-rings that have non-linear load-deection
characteristics.
The work in Ref. [13] has proposed a DVA for a
cantilever turning tool for vibration suppression during
cutting operation. The DVA is once again modelled as an
inertial mass on a spring with viscous damping. However,
in practical implementation, a piezoelectric inertia actuator
emulates the DVA system with a damping ratio of 0.13.
Natural frequency of the inertial actuator can be tuned to
the cutting tool frequency, in this case by changing inertia
mass. This work reports a reduction of 30 g in acceleration
amplitude, measured on the cutting tool equipped with
the DVA.

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A. Rashid, C.M. Nicolescu / International Journal of Machine Tools & Manufacture 48 (2008) 10361053

While this kind of damping treatments have been

successfully applied to cutting tools in turning operations,
their implementation in milling or drilling operations is not
practical due to rotating tools. The work in Ref. [14] is purely
of theoretical nature, where the authors have proposed a
design concept for an optimal passive DVA in milling
process. The DVA is once again modelled as a mass with
spring and viscous damper and applied to the milling system.
In this case, the absorber is shown to be improving the
stability limits of a milling operation. The concept is studied
analytically and veried through numerical simulation.
1.1. Tuned dampers in millingan alternative
solution approach
It is known that productivity and accuracy/surface nish
in a machining operation are, by and large, determined by
the static and/or dynamic stiffness of the machinexturetoolworkpiece system, i.e. the elastic structure of the
machining system [12]. Considering machining process as a
closed-loop system comprising the elastic structure
including machine tool, cutting tool and workpiece/workholding xture systemand the cutting process, dynamic
stability of the system will be affected most by addressing
the weakest component in the elastic chain. However,
improvement in dynamic stiffness of any of the components will improve stability of the system and thus its
overall response. This approach allows us to use workpiece
and/or workholding xture for vibration control in milling.
These two being the stationary components of the system
provide us the same ease of designing and implementing a
tuned damper as a stationary tool in case of turning
operations. Due to complex and modular nature of
conventional xture systems, this approach is not very
practical. However, it can be applied successfully, as will be

shown later, in case of palletised workholding systems.

Design of the palletised workholding systems is very
compact with the whole xture system comprising only
two major components, i.e. a receiver chuck and a
reference pallet. These systems add great exibility in
milling operations by allowing the cutting tool to access at
least ve sides of a cubic workpiece freely. However, this
exibility makes the workpieceworkholding system more
prone to vibration and thus calls out for a more effective
and convenient control strategy.
This research is an effort to develop an efcient method
of design and easy implementation of tuned viscoelastic
dampers (TVDs) to control vibration in a milling process.
This design and development process employs an analytical
TVD model in combination with experimental dynamic
model of a workpieceworkholding system, i.e. the main
system. In this process, frequency response function (FRF)
of the main system, xed on the table of a milling machine,
is measured through modal impact testing. After a quick
analysis of the FRF data, a vibration mode of interest is
selected to calculate design parameters of a TVD for
damping the target mode. Following this, the analytical
TVD (design parameters) is applied to the experimental
FRF of the main system through an analytical model for
TVD design. Benet of this approach is that the design
parameters of the TVD are optimised by applying it
directly to the real model of the main system which ensures
efcient design with reliable performance. Fig. 1 presents a
sequential summary of the analysis, design and implementation work compiled in this paper.
2. Modelling tuned viscoelastic dampers
TVDs which make use of viscoelastic polymers are
modelled as simple masses attached to viscoelastic spring

Analysis of TVD Model with simulated data

Simulated FRF data of a 3DOF system generated
Analytical TVD applied to the simulated FRF
Model validated
Analysis of TVD Model with experimental data
FRF data of a workholding system acquired by Modal Impact testing
Analytical TVD applied to the experimental FRF
Design parameters obtained
Design and analysis of experimental TVDs
TVDs designed based on parameters used in analytical design
TVDs placed on a steel workpiece held with the workholding system
Evaluation of TVDs performance by Experimental Modal Analysis
Machining tests for evaluating the experimental TVDs
Milling of the workpiece with and without the TVDs
Vibration measurements during the milling operations
Evaluation of TVDs performance during the machining tests
Fig. 1. Sequential summary of the analysis and design process.

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elements (damping polymers). For best performance, i.e.

maximum reduction in vibration amplitude, a TVD should
be attached to a vibrating structure at a point of highest
vibration amplitude. In such conguration, a TVD
generates an opposing force at the point of attachment
that restrains the motion of the structure at this point and
thus reduces amplitude of the structural vibration to forces
of excitation. Fig. 2 outlines the basic conguration of a
TVD.
If the point of damper attachment on the structure is
vibrating harmonically with amplitude X0 at frequency o,
then equation of the motion of the damper mass is given as
k xt  X 0 expiot 0,
mxt

k X 0 expiot
.
(2)
k  mo2
Force applied by the vibrating damper at the point of
attachment on the structure should be equal to k xt
X 0 expiot. If this force f(t) is given as f t F D exp
iot, then the opposing force FD is given by
xt

k X 0 mo2
.
(3)
k  mo2
When an SDOF system is equipped with a tuned
damper, it becomes a two-DOF system having two
equations of motion. If we consider our structure in Fig.
2 as a single mass M connected to ground via a spring K
and excited by a harmonic force F, then equations of this
system equipped with a TVD can be written as

FD 

M X KX k X  x F expiot,

(4a)

mx k x  X 0.

(4b)

Assuming a steady-state response of the form

X X0 exp(iot) and solving the equations mutually for
response of the structural mass M, when it is equipped with
the TVD, we get an expression as follows:
F k  mo2
.
k  mo2 K  Mo2  k mo2

TVD
m

Solving this equation for X0 results in same expression as

given in Eq. (5). This alternative approach is more useful in
designing TVDs for multi-degree of freedom (MDOF)
systems [15].
2.1. Designing TVD for a simulated MDOF system
In case of complex MDOF systems, a convenient
approach in designing a TVD is to consider the damper
as a means of external force applied at the point of
attachment. Response of the main system without the TVD
can be expressed in the form:
X 1 o a11 oF 1 ,

(7)

where F1 is the harmonically varying force applied to mass

1 of the main system, X1 is the resulting steady-state
harmonic response of mass 1 and a11 is transfer receptance
measured at mass 1. Feasibility of this approach is
demonstrated through a simulated three-DOF system, as
shown in Fig. 3.
Displacements X1, X2 and X3 of the three masses can be
given as function of receptances and applied forces as
follows:
X 1 a11 F 1  F D a12 F 2 a13 F 3 ,

(8a)

X 2 a21 F 1  F D a22 F 2 a23 F 3 ,

(8b)

X 3 a31 F 1  F D a32 F 2 a33 F 3 .

(8c)

If the TVD is intended for vibration attenuation of mass

M1 of the main system we shall refer to Eq. (8a). This
equation can be simplied further if the excitation force
acts on M1 only. In this case, we are left with part of the
Eq. (8a) as follows:
X 1 a11 F 1  F D

(9)
x

(5)
m

X1

An alternative approach is to regard the TVD as a means

of applying an external force f(t) FD exp(iot), where FD
is already given by Eq. (3).
x(t)

Using this approach results in single equation for the

motion of the structural mass M that can be written as
follows:


k mo2
X F expiot
(6)
M X K  
k  mo2

(1)

k* in the above equation is complex stiffness of the

viscoelastic spring and is given as k(1+iZ).
Assuming a steady-state response xt x0 expiot for
the damper, Eq. (1) can be solved for x(t) as

X0

Viscoelastic
spring
k(1+i)

k = k(1+)

M1
K1

X2

F1
F2

M2
K2
X3

F3

M3
X(t)

Main Structure
M
Fig. 2. Tuned viscoelastic damper.

1039

K3
Fig. 3. Three-DOF system equipped with a TVD.

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1040

Substituting FD for its expression as given by Eq. (3), we

obtain the following:
X 1 a11 F 1 a11

k mo2 X 1
k  mo2

(10)

By collecting the terms in X1, we reach to the expression:

aD
11

X1
a11 k  mo2

F 1 k  mo2  a11 k mo2

From the outcome of the analytical design process, it can

be concluded that




(11)

Here, k* k(1+iZ) with k being the elastic stiffness of the

TVD spring. aD
11 is the receptance of the system equipped
with the TVD as compared to a11, which is the receptance
for the system without the TVD.
The three-DOF system is simulated with the following
parameters:
M 1 2 kg;
M 2 1 kg;
M 3 3 kg;

the TVD parameters, i.e. the mass m and stiffness k are

designed correctly;
an increase in Z value reduces the amplitude of new
modes arising due to the TVD and a value of 0.1 is
optimal as it suppresses the peaks A and B with a
very shallow trough C (see Fig. 5);
the analytical model is working correctly and it can be
used effectively in designing appropriate TVD in
combination with FRF data from MDOF systems.

The three-DOF model used here has a correspondence

with the dynamic model of the actual workholding system
used in experimental work, both in terms of the degrees
of freedom and modal frequencies; as we will see in the
following analysis.

K 1 K 2 K 3 1:0E 08 N=m:

3. Designing TVD for a palletised workholding system

Response of the main system at mass M1 is calculated

without the TVD, rst. An FRF with three undamped
modes is obtained. Third mode of the system at 2489 Hz is
selected as target mode for the intended TVD. Based on the
mode frequency and a restriction on mass of the TVD to be
5% of mass M1, stiffness of the viscoelastic link between
mass M1 and the TVD mass m is calculated to be
2.45E+7 N/m. New FRF of the main system equipped
with the TVD is obtained. Since the TVD is designed
without any damping, i.e. Z 0, its behaviour should be
like a dynamic absorber giving rise to two new modes while
suppressing the target mode. In order to study the effect of
damping, the Z value is varied between 0.01 and 0.1. Fig. 4
shows FRF a11 of the three-DOF system shown in Fig. 3,
both without and with TVD having different loss factor
values.

In the next stage, the TVD model is validated using

experimental FRF data. The purpose is to show that the
analytical model can be used in designing a real TVD by
making use of FRF data of a real system instead of a
simulated one. This is done here by acquiring FRF data of
a workholding system equipped with a steel workpiece [16].
A commercially available palletised workholding system
manufactured by System 3R International AB is used for
this work. This pallet system, named MACRO, comprises a
receiver chuck, a draw bar and a reference pallet. A
workpiece is xed on the pallet using four screws. The
pallet, containing the workpiece, is then placed on
precision ground references of the receiver chuck through
an intermediate coupling element, i.e. the draw bar. The
chuck has pneumatically controlled high-power mechanical
springs that, through the draw bar, pull the pallet down

Fig. 4. Direct receptance a11 of the three-DOF system of Fig. 3 with design parameters m1 2 kg, m2 1 kg and m3 3 kg, k1 k2 k3 1.0E+8 N/m.

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1041

Fig. 5. Magnied view of Fig. 4 showing the 3rd system mode as affected by the application of the TVD.

z
Workpiece

x
y

Pallet

Workpiece-Pallet Interface
Drawbar

Pallet-Chuck Interface
Plate-Machine
Table Interface
Chuck
Machine
Table

Fig. 6. Assembly sequence for MACRO chuckpallet system and dynamic model of the system. The cubic workpiece held on the system is accessible for
machining from ve sides at least.

with a high force and place it on X, Y and Z references of

the chuck. This high-accuracy and high-repeatability
reference system secures the workpiece in place during a
machining operation. Assembly sequence for a typical
chuckpallet system with a schematic of its dynamic design
is shown in Fig. 6.
A carbon steel workpiece of dimensions 73  73  73 mm
is xed on the MACRO chuck that is xed on the table of a
milling machine. Dynamic characteristics of this set-up are
obtained through modal impact testing in the three
orthogonal coordinates namely X, Y and Z. The FRFs of
the system measured in the three coordinates are compared
in Fig. 7.

Since in milling the cutting forces in the XY plane are of

major concern, we are more interested in dynamic response
of the system in X and Y coordinates. Analysis of the FRF
data shows that the system has three major vibration modes
in the frequency range of interest in XY plane. The 1st mode
is at 773 Hz, 2nd at 1228 Hz and the 3rd at 2680 Hz. Mode
shape analysis showed that the 1st and 2nd mode in X and Y
coordinates, respectively, are bending motion, whereas the
3rd mode, which is common in the two coordinates, is of
torsional nature. Further analysis revealed that the torsional
mode is a relative motion at the palletchuck interface of the
workholding system. Response in Z coordinate has only one
signicant mode close to 3500 Hz.

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Since the torsion mode at 2680 Hz is common to the

two planar coordinates X and Y and has the highest
amplitude with greatest probability of excitation during a
machining operation, it is selected as target mode for the
TVD design.
3.1. Testing experimental data with analytical TVD
Before designing a real TVD, an analytical analysis of
the design parameters is carried out in combination with
experimentally measured FRFs. For this purpose, the
inertance measured in the X coordinate is converted to
receptance. Tuning parameters for the damper are described by the mass and the stiffness of the damper. The
mass of the TVD is restricted to 5% of the workpiece mass.
Since the mass of the steel workpiece is 3 kg, the damper
mass becomes 0.15 kg. Using this mass and the frequency

of the target mode, i.e. 2680 Hz, the design stiffness is

calculated to be 4.25E+7 N/m, using the relation
o2n k=m. An analytical TVD with these design values is
applied to the experimental FRF in X coordinate using
Eq. (11). Fig. 8 compares the FRF of the actual system to
that with an analytical TVD having Z value set to zero. The
gure clearly shows that the damper has been designed
correctly for the target frequency. However, the behaviour
of this damper is like a typical dynamic absorber giving rise
to two modes on both sides of the target frequency.
Addition of the damper also shows its effect on the rst
mode that assumes a slightly lower frequency. The peaks
A, B and C in the gure can be minimised by introducing
suitable value of the loss factor Z.
In the next step, the analytical TVD is designed with
different values of Z ranging from 0.2 to 1.0. Fig. 9 shows a
comparison among TVDs designed with different values of
the loss factor. The FRFs with different Z values show that
there is an optimum value of the loss factor which reduces
the peaks A and B in Fig. 8 to minimum. In this case, the
optimum value is 0.4 because the response at the target
frequency has a smoother prole than all the other values
used in the analysis.
Results of the analysis in this section demonstrate
effective use of analytical modelling in combination with
experimental FRF data. This design approach is very
reliable, as the design parameters of the TVD are obtained
by using FRF data of the actual system and also very
useful as the FRF data of a new workpiece size, material or
other variations can be obtained easily to redesign the TVD
if necessary.
3.2. Designing experimental TVD

Fig. 7. Modal impact testing of the MACRO workholding system xed

on the machine table. The system was holding a carbon steel workpiece of
dimensions 73  73  73 mm. Dynamic responses (inertance) of the system
in three orthogonal coordinates, i.e. X, Y and Z are compared.

Following this analytical design, a real TVD is prepared

by selecting suitable materials both for the damper mass
and the viscoelastic spring. High-density metallic carbide

Fig. 8. Effect of an analytical damper applied to experimental FRF (receptance) of the undamped MACRO. The damper loss factor in this case is set to
zero.

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1043

Fig. 9. Effect of analytical TVDs applied to experimental FRF (receptance) of the undamped MACRO. The TVD loss factors are 0.2, 0.4, 0.6 and 1.0.

material is used to maintain the damper mass of 0.15 kg

with its dimensions as small as possible, which is 25  25 
15 mm.

Table 1
Data for the viscoelastic polymer 3M-112 at 25 1C (extracted from the
material specication sheet)
Frequency (Hz)

3.2.1. Selection of viscoelastic damping polymer

While selecting an appropriate viscoelastic material for
the intended TVD design three factors, maximum loss
factor, maximum shear modulus and variation of these
parameters with both frequency and temperature are
considered. A very important consideration is the variation
of the shear modulus with temperature. Since the temperature in the material can increase during its use due to
energy dissipation, the shear stiffness of the viscoelastic
spring of the TVD can change appreciably. This will in turn
change natural frequency of the TVD thus deteriorating its
performance on the frequency it is designed for. Therefore,
ideally the temperature-dependant change in the shear
modulus should be as low as possible in the range of
application.
One of the commercially available viscoelastic damping
polymers, 3M-112 is found to be the most suitable. This
material has high loss factor, comparatively moderate
value of the modulus and moderate variation of the two
parameters in the design range of temperature and
frequency. Other considerations for the selection were
availability and ease of application. Design data for the
selected material, as extracted from its specication sheet,
is summarised in Table 1. It is important to mention here
that this material has a loss factor of about 0.57 at the
target frequency which is higher than the required
optimum value of 0.4, as indicated by the analysis shown
in Fig. 9. Therefore, it is expected that the FRF of the
system with this TVD would be comparable to the one with
loss factor of 0.6 in Fig. 9.
In order to maintain the stiffness of the viscoelastic link
to 4.25E+7 N/m, required thickness of the damping
polymer is calculated by using the shear modulus value

1000
3000

At 25 1C
G (MPa)

6
11

0.75
0.55

given in Table 1. Features of the nal TVD design are given

as follows:





Mass: 150 g
Dimensions: 25  25  15 mm
Damping polymer thickness: 0.16 mm

This TVD is placed on top corner of the workpiece, so

that the viscoelastic polymer would act in shear in both
bending (in X coordinate) and torsion vibration modes.
Results from modal impact test of the system, equipped
with the TVD, are shown in Fig. 10. Here the FRF of the
damped system is compared with that of the undamped
system and the system with the analytical TVD of the same
design parameters as presented in Fig. 9.
The FRFs of the system with analytical and experimental TVD are in very good agreement with each other.
Reduction in vibration amplitude is observed on both the
bending (1228 Hz) and torsion (2680 Hz) modes; obviously,
it is maximum for the later one. The amplitude of
acceleration (see Fig. 11) at the target mode of the TVD,
i.e. 2680 Hz is reduced by 20 dB and by 3.5 dB at 1228 Hz.
Since the TVD has been designed for use in machining of
the workpiece, it is not practical to place it on top of the
workpiece. The best possible location would obviously be
the one most remote from the cutting tool. Since the energy
input to the damper is highest when placed on top of the

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Fig. 10. Comparing FRF (receptance) plots of the MACRO system damped with an analytical TVD (m 0.15 kg, k 4.25E+7, h 0.6) and an
experimental TVD (m 0.15 kg, viscoelastic polymer thickness 0.16 mm).

Fig. 11. Comparing FRF (inertance) plots of system damped with an analytical TVD (m 0.15 kg, k 4.25E+7, h 0.6) and an experimental TVD
(m 0.15 kg, viscoelastic polymer thickness 0.16 mm).

workpiece, at least for the bending mode, and so is its

damping efciency, placing it at a remote location might
decrease its efciency. However, for practical reasons,
the TVD has to be placed at the bottom corner of the
workpiece. Modal impact tests are performed again with
new TVD location and the resulting FRF is compared with
that of former location. Fig. 12 compares the effect of the
damper when placed on the top with that at the bottom of
the workpiece. This comparison shows that the damper
efciency is slightly reduced and the vibration amplitude at
the two modes has increased slightly. However, this
increase (1 dB for the bending and 2 dB for the rotational
mode) is rather low when compared with the amplitudes of
the system without the TVD.
The analytical analysis showed that increasing the
number of TVDs of exactly the same design can

compensate for the reduced efciency of the damper due

to change of its location. In order to apply four TVDs, the
damper stiffness and mass in the analytical analysis were
increased four times and the loss factor was maintained
at 0.6. Fig. 13 compares the effect of four analytical
TVDs with that of one experimental TVD. It clearly
shows that four TVDs are more effective in reducing
amplitude of the target mode bringing it down to the level
of elimination.
Modal impact testing of the system with four TVDs
(see test set-up in Fig. 14) showed signicant reduction in
vibration amplitude of both modes, as shown in Fig. 15. In
this case, the torsion mode is almost eliminated and the
amplitude of the bending mode is reduced almost by 7 dB.
When the FRF with four experimental TVDs is
compared to the one with four analytical TVDs, shown

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Fig. 12. Comparison of system responsethe TVD on top to that at bottom of the workpiece.

Fig. 13. Comparison of system responsefour analytical to that of one experimental TVD at bottom of the workpiece.

Fig. 14. The impact-testing set-up: the MACRO workholding system

holding the steel workpiece equipped with four TVDs.

in Fig. 16, the two FRFs follow each other very well except
in the anti-resonance regions.
After this detailed analysis in X coordinate, the system
with four experimental TVDs is tested in the other two
coordinates, i.e. Y and Z as well. The modal analysis of the
undamped system in these coordinates shows that response
in Y coordinate is more or less the same as in the X
coordinate except an additional bending mode around
750 Hz and with two peaks in the vicinity of 1250 Hz. These
two peaks have amplitude one-third of that in X coordinate
in the same frequency region. Response in Z coordinate
has only one signicant mode in the vicinity of 3500 Hz.
The analysis with the TVDs showed that the torsion mode
in the Y coordinate is damped to the same extent as in the
X coordinate. Since the amplitude of the bending mode in
Y coordinate is very low and also the dampers are not
acting in shear for this mode, their effect is not very

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Fig. 15. Comparison of system responseone TVD at bottom to that of four at bottom of the workpiece.

Fig. 16. Comparison of system responsefour analytical to that of four experimental TVDs at bottom of the workpiece.

pronounced. However, a more interesting observation is

the damping of high-frequency mode in the Z coordinate,
where the amplitude of acceleration response at 3500 Hz is
reduced from 6.6 to 4.25 m/(s2/N). The FRFs of the
undamped and the damped system in the three coordinates
are compared in Fig. 17. This analysis shows that the
TVDs are effective in a very broad frequency range and
improve the dynamic response in all the three coordinates
to a varying extent though. Following the analytical and
experimental analysis, efciency of the TVDs is validated
through machining tests.
4. The machining tests
The machining tests are carried out for validating the
performance of the TVDs as observed during the analytical
and experimental design process. The tests are executed on
the steel workpiece in a milling machine. The cutting

parameters, as given in Table 2, are used for an end milling

operation on the steel workpiece.
Four TVDs are attached at the bottom of the workpiece.
Vibration amplitudes (acceleration) are measured during
the milling operation by using a tri-axial accelerometer
placed on the workpiece. The signatures of the undamped
system are compared with those of the damped system. The
milling set-up for steel workpiece equipped with four TVDs
is shown in Fig. 18.
Signals are measured in three coordinates, i.e. X, Y and
Z, as shown in Fig. 18. Fig. 19 compares time domain
vibration amplitudes of the undamped system with the
damped system in X coordinate. The comparison shows
that average value of acceleration is reduced from 160 to
110 m/s2, which amounts to a reduction of 5 g.
Data comparison from the same cut but in Y coordinate
is presented in Fig. 20. The TVDs appear to work more
efciently in Y coordinate than in the X, as the amplitude is

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Fig. 17. Modal impact testing of the MACRO workholding system with the steel workpiece of dimensions 73  73  73 mm. Dynamic responses of the
system in X, Y and Z coordinates are compared while testing with (dashed line plots) and without (solid line plots) the TVD.

Table 2
Milling test parameters
Parameter
Workpiece

Unit
Material
Size

Tool
Tool diameter
Number of cutting edges
Tool hangout
Cutting speed
Feed rate
Depth of cut, axial (ap)
Depth of cut, radial (ae)

mm

Carbon Steel
73  73  73

End-mill
mm

mm
(m/min)/rpm
(mm/min)/mm/rev
mm
mm

Coated inserts
20
3
46
(150)/2385
238.50/0.1
10
1

reduced from 875 to 504 m/s2 amounting to a reduction of

about 38 g.
If we analyse the data thoroughly, we can clearly see that
the impacts from the cutting edge engagement produce
a peak of lower amplitude in case of damped system
(Fig. 21). Furthermore, the vibration due to impact from
one cutting edge is already attenuated to almost zero before
another impact form the next edge. However, in case of
undamped system, certain level of vibration always exist inbetween the two impacts. This situation may cause
continuous built of energy into the system resulting in
chatter.

Fig. 18. The milling set-up for steel workpiece equipped with four TVDs
and a tri-axial accelerometer for measuring vibration acceleration.

If we analyse the data in the frequency domain, it

becomes evident that the TVDs are working efciently not
just on the target frequency but also on the neighbouring
frequencies. Fig. 22 compares spectrums of measurements
in X coordinate showing the effectiveness of the dampers
on a broad frequency range.
In order to strengthen the foundation of TVD working
here, further machining tests are performed with different

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combinations of cutting speed and feed rate. Four feed

rates and four cutting speeds are used in combination such
that each feed rate is used with all four cutting speeds.
Table 3 summarises the cutting parameters used in this
testing.
Although tests are made with several combinations
of the speed and feed, only four combinations presented
here are found enough to understand the working of
TVDs. Fig. 23 compares spectrum of measurements in X
and Y coordinates for cutting speed of 126 m/min
(2000 rpm) and feed rate of 500 mm/min (0.25 mm/rev). It
is clear that the vibration amplitudes in the frequency range

Fig. 19. Time history of vibration amplitudes as measured in X coordinate

during milling of the steel workpiece: response of the system without
(upper) and with (lower) TVDs. With TVDs, the steady-state maximum
reduces from 160 to 110 m/s2.

25002900 Hz around the target mode 2680 Hz are still

dominantly excited in the system without TVDs. In
comparison, the vibration in the same frequency range is
almost insignicant for the system with TVDs. In addition,
the amplitudes in the range of bending mode, i.e. 1228 Hz
are also lower for the system with TVDs.
Fig. 24 presents same kind of comparison for a different
combination of cutting speed and feed rate, i.e. 5000 rpm
and 0.1 mm/rev, respectively. Although both the speed and
feed per revolution have changed, the natural frequencies
of the system without TVDs are still excited signicantly
and their amplitudes are drastically reduced with the
application of TVDs.

Fig. 21. Comparison of vibration amplitudes in Y coordinate during an

interval of 30 ms.

Fig. 20. Time history of vibration amplitudes as measured in Y coordinate during milling of the steel workpiece: response of the system without (upper)
and with (lower) TVDs. With TVDs, the steady-state maximum reduces from 875 to 504 m/s2.

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Fig. 22. Vibration spectrum as measured in X and Y coordinates during milling of the steel workpiece: response of the system without and with TVDs.
The system with TVDs has a very low level of vibration in a broad frequency range around the target frequency of 2680 Hz and also around the other
natural frequency of the system, i.e. 1228 Hz.

Table 3
Milling test parameters with several combinations of cutting speed and
feed rate
Parameter

Unit

Range

Cutting speed
Feed rate
Depth of cut, axial (ap)
Depth of cut, radial (ae)

(m/min)/rpm
(mm/min)/mm/rev
mm
mm

(126315)/20005000
(500800)/0.10.4
10
0.5

Same behaviour can be observed in Figs. 25 and 26 that

present data for a higher feed rate, i.e. 800 mm/min. The
amplitudes in the target frequency range are once again
excited heavily for the two cutting speeds, i.e. 126 and
315 m/min while milling without TVDs. These amplitudes
reduce to comparatively negligible values with the use of
TVDs.
5. Discussion
Stability of a milling process depends on the dynamic
characteristics of the machinetoolworkpieceworkholding system. Chatter is always associated with one of
the natural frequencies of this system and can be avoided
by controlling the dynamic response of the components
in the system. In this work, response of the workpiece
workholding system is controlled by the application of
TVDs targeting one of the natural frequencies of the
system that is most prone to excitation. In doing so,
an analytical model dening the TVD as an externally

applied force is tested rst with FRF of a simulated

three-DOF system. Application of the analytical TVD on
the simulated FRF reduces the amplitude of the target
natural frequency (mode) of the system as expected and
proves correctness of the model. Following this,
the analytical model of the TVD is tested with experimental dynamic model (FRF) of the workpieceworkholding system. Comparison of the FRF of the system with
and without the analytical TVD shows that the amplitude
of the target mode of the system is reduced signicantly.
The TVD model responds to variations in the design
parameters effectively. For example, it can be seen that
increase in the loss factor reduces the amplitudes of
the auxiliary modes arising from the application of a
TVD with zero loss factor. Response of the main system
at the target mode is optimised by studying the inuence of different parameters and then choosing the best
combination for actual design. Optimisation of design
parameters through combination of experimental model of
the system and analytical model of the TVD is unique and
efcient.
The experimental TVD designed using the optimum
parameters is placed on the workpiece. Impact testing
shows that FRF of the system with one experimental TVD
follows the course exactly as predicted by the analytical
analysis. This is also true for the system with four TVDs.
Application of one TVD reduces acceleration amplitude of
the target mode by 20 dB and increasing the TVDs to four
nearly eliminates the target mode. In other words, the
system with four TVDs is capable of withstanding much
higher dynamic forces without the target mode being

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Fig. 23. Vibration spectrum measured in X and Y coordinates while milling with parameters ap 10 mm, ae 0.5 mm, vc 126 m/min (2000 rpm) and
vf 500 mm/min (0.25 mm/rev).

Fig. 24. Vibration spectrum measured in X and Y coordinates while milling with parameters ap 10 mm, ae 0.5 mm, vc 315 m/min (5000 rpm) and
vf 500 mm/min (0.1 mm/rev).

excited. Testing of the system also shows that the TVDs are
effective over a wide range of frequency with varying
efciency though. The amplitude of acceleration at

1228 Hz, a mode far from the target mode, is also reduced
signicantly, i.e by 3 and 7 dB in case of one TVD and four
TVDs, respectively.

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Fig. 25. Vibration spectrum measured in X and Y coordinates while milling with parameters ap 10 mm, ae 0.5 mm, vc 126 m/min (2000 rpm) and
vf 800 mm/min (0.4 mm/rev).

Fig. 26. Vibration spectrum measured in X and Y coordinates while milling with parameters ap 10 mm, ae 0.5 mm, vc 315 m/min (5000 rpm) and
vf 800 mm/min (0.16 mm/rev).

The milling tests conrm that the TVDs work effectively

in controlling the vibration amplitude at the target natural
frequency of the system. Comparison of the vibration

response of system with and without the TVDs during the

milling tests shows that vibration amplitudes are reduced
drastically in the vicinity of the target mode (2680 Hz).

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Table 4
Comparison of maximum vibration amplitudes at the excited natural frequencies during milling tests with and without TVDs
Milling parameters

Coordinate

Excited frequency (Hz)

Vibration amplitude (m/s2)

Without TVD

N 2000 rpm, vf 500 mm/min

X
Y

N 5000 rpm, vf 500 mm/min

X
Y

N 2000 rpm, vf 800 mm/min

X
Y

N 5000 rpm, vf 800mm/min

X
Y

With TVD

% Reduction

1300
2700
1300
2700

14.9
17.7
17.7
18.7

7.9
0.7
10.1
0.5

47
96
43
97

1250
2750
1250
2750

62.8
61.1
68.0
65.6

53.8
5.9
68.0
5.6

14
90
0
91

1300
2700
1300
2700

15.5
17.6
18.9
40.1

1250
2750
1250
2750

62.0
80.0
66.0
150

7.47
0.4
8.9
0.6
51.0
5.9
66.0
9.6

51
98
53
98
18
93
0
94

The axial depth of cut (ap 10 mm) and the radial depth of cut (ae 0.5 mm) remain unchanged. The values in bold indicate the frequency close to the
target frequency of the TVDs.

The amplitudes in the vicinity of the non-target mode

(1228 Hz) are also reduced signicantly. Test results with
different combinations of the cutting parameters with
variations in speed and feed rate show that the modes close
to the target mode are excited in all combinations tested
here and the TVDs work effectively to reduce their
amplitudes. Table 4 gives a quantitative summary of
vibration amplitudes of the excited natural frequencies
during milling with and without TVDs.
It is important to emphasise here that the natural
frequency of the target mode is a function of the dynamic
characteristics of the workpieceworkholding system and
the number of TVDs used for vibration attenuation will
only control the amplitude of this mode. Moreover, in
order to design TVDs for the target mode, the design
stiffness does not depend on the cutting parameters but
only on the frequency of the mode.
The TVDs, either one or four, target the same vibration
mode and this characteristic of such vibration control
method is not affected by variations in cutting parameters
such as cutting speed, feed rate and depth of cut. The
TVDs will always work whenever the target vibration
mode is excited during milling regardless of what combination of cutting parameters is used. However, the intensity
of excitation may vary signicantly with varying parameters and so may the performance of the TVDs. If a
particular combination of cutting parameters excites the
target mode more vigorously than other, the use of four
TVDs will be more effective than one or two in keeping the
vibration below the chatter thresh hold. However, if the
given combination of cutting parameters does not excite
the target mode at all, the TVDs will not be effective
regardless of their quantity in use.

6. Conclusions
This work concludes that







Workpieceworkholding system is an important component of the elastic chain of a machining system and
plays a vital role in dening dynamic characteristics of
the machining process.
In a palletised workholding system, the workpiece can
be used effectively for vibration control in milling
processes through the application of TVDs.
The force model used in designing the TVD is accurate
and provides the convenience of using experimental
model of the system obtained through modal impact
testing in the form of frequency response function
(FRF).
The TVDs are effective in a wide range of frequency
excitation; as shown by the modal impact test results,
the mode far from the target mode is also reduced by
7 dB.
During milling, the TVDs reduce the vibration amplitudes up to 98% in the target mode range and up to
53% in the non-target mode range.
The design parameters of TVDs are a function of the
natural frequencies of the workpieceworkholding
system and not of the cutting parameters. If any given
combination of the parameters excites the target natural
frequency of the system, the TVDs designed for this
frequency will always reduce the corresponding vibration amplitude.

Main strength of this design approach is that it uses experimental dynamic model of the workpieceworkholding

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system in combination with the analytical model of the

TVD. This makes the design process efcient and the
TVDs extremely effective. Design process based on a pure
analytical approach will be inefcient due to the large
amount of time required for obtaining an accurate model
of the system and the various assumptions made during its
modelling. Combination of the real system model with the
analytical model of the TVD is both unique and useful.
Acknowledgement
System 3R International AB, Stockholm, Sweden, is
acknowledged for its support.
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