A composite structure device: vibration control and energy harvesting of tool system in aviation thin-walled parts milling process

Abstract The intense vibration generated by the high-speed milling cutter in the processing process not only seriously affects the surface roughness but also may damage important components of the machine tool, resulting in significant economic losses. Therefore, a composite structure of piezoelectric energy-collector (PEC) and nonlinear energy sink (NES) is innovatively constructed by combining theoretical research and numerical analysis to achieve more efficient vibration suppression and energy recovery in milling. Using the Hamilton principle, the electromechanical model of the composite structure is developed. Then, based on the Galerkin truncation to discretized displacement functions, we solve the amplitude-frequency response of the tool structure by using the harmonic balance method. The validity analysis of the proposed method can be verified by rigorous comparison with the results of the Runge-Kutta method. A novel NES-PEC composite structure presented in this work shows excellent vibration suppression capability in the milling process. More importantly, the structure also enables self-powered sensing of the tool system, significantly reducing dependence on external power sources. This innovative design substantially improves the stability and reliability of milling processes and opens up new ways to optimize the energy efficiency of tool systems. In summary, this paper’s modeling and solving methods, vibration reduction techniques, and energy harvesting strategies have laid a solid foundation for applying a high-speed milling cutter system. More relevant literature on applying vibration suppression and energy harvesting devices in milling must be reviewed. This paper fills in the research gap and provides a valuable reference for future tool systems design and optimization.