Chatter suppression in large overhang face milling using a toolholder with high dynamic performance


There is increasing demand for the large overhang toolholder to machine certain workpieces with complex cavities during milling operation, but this kind of toolholder may bring an undesired source of chatter. This paper develops a novel toolholder with high dynamic performance to suppress chatter. Firstly, the dynamics of the milling cutter are investigated according to the cantilever beam theory. The obtained analysis result shows that the increasing stiffness and damping ratio can effectively reduce the vibration amplitude; based on this finding, a novel toolholder is developed through embedding the strips and damping core into the toolholder body. Subsequently, the dynamic characteristic of the novel toolholder is studied qualitatively by the complex number method, and its geometrical parameters are optimized by the finite element method. Finally, modal tests and milling experiments are conducted to verify the chatter stability improvement of the novel toolholder. The experimental results demonstrate that the chatter stability of the developed toolholder is enhanced significantly.

This is a preview of subscription content, log in to check access.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19


  1. 1.

    Wan M, Dang XB, Zhang WH, Yang Y (2018) Optimization and improvement of stable processing condition by attaching additional masses for milling of thin-walled workpiece. Mech Syst Signal Process 103:196–215

    Article  Google Scholar 

  2. 2.

    Quintana G, Ciurana J (2011) Chatter in machining processes: a review. Int J Mach Tools Manuf 51(5):363–376

    Article  Google Scholar 

  3. 3.

    Munoa J, Beudaert X, Dombovari Z, Altintas Y, Budak E, Brecher C, Stepan G (2016) Chatter suppression techniques in metal cutting. CIRP Ann Manuf Technol 65(2):785–808

    Article  Google Scholar 

  4. 4.

    Yue CX, Gao HN, Liu XL, Liang SY, Wang LH (2019) A review of chatter vibration research in milling. Chin J Aeronaut 32(2):215–242

    Article  Google Scholar 

  5. 5.

    Ji YJ, Wang XB, Liu ZB, Wang HJ, Yan ZH (2018) An updated full-discretization milling stability prediction method based on the higher-order Hermite-Newton interpolation polynomial. Int J Adv Manuf Technol 95(5):2227–2242

    Article  Google Scholar 

  6. 6.

    Mei YG, Mo R, Sun HB, He BB, Wan N (2019) Stability prediction in milling based on linear multistep method. Int J Adv Manuf Technol 105(5):2677–2688

    Article  Google Scholar 

  7. 7.

    Feng J, Hou N, Jian Z, Sun Z, Zhang J (2020) An efficient method to predict the chatter stability of titanium alloy thin-walled workpieces during high-speed milling by considering varying dynamic parameters. Int J Adv Manuf Technol 106(11):5407–5420

    Article  Google Scholar 

  8. 8.

    Li K, He S, Li B, Liu HQ, Mao XY, Shi CM (2020) A novel online chatter detection method in milling process based on multiscale entropy and gradient tree boosting. Mech Syst Signal Process 135:106385

    Article  Google Scholar 

  9. 9.

    Gao J, Song QH, Liu ZQ (2018) Chatter detection and stability region acquisition in thin-walled workpiece milling based on CMWT. Int J Adv Manuf Technol 98(1):699–713

    Article  Google Scholar 

  10. 10.

    Chen Y, Li HZ, Hou L, Bu XJ (2019) Feature extraction using dominant frequency bands and time-frequency image analysis for chatter detection in milling. Precis Eng 56:235–245

    Article  Google Scholar 

  11. 11.

    Chen ZZ, Li ZL, Niu JB, Zhu LM (2020) Chatter detection in milling processes using frequency-domain Rényi entropy. Int J Adv Manuf Technol 106(3):877–890

    Article  Google Scholar 

  12. 12.

    Munoa J, Beudaert X, Erkorkmaz K, Iglesias A, Barrios A, Zatarain M (2015) Active suppression of structural chatter vibrations using machine drives and accelerometers. CIRP Ann Manuf Technol 64(1):385–388

    Article  Google Scholar 

  13. 13.

    Wang SY, Song QH, Liu ZQ (2019) Vibration suppression of thin-walled workpiece milling using a time-space varying PD control method via piezoelectric actuator. Int J Adv Manuf Technol 105(7):2843–2856

    Article  Google Scholar 

  14. 14.

    Song QH, Shi JH, Liu ZQ, Wan Y, Xia F (2016) Boring bar with constrained layer damper for improving process stability. Int J Adv Manuf Technol 83:1951–1966

    Article  Google Scholar 

  15. 15.

    Hahn RS (1951) Design of lanchester damper for elimination of metal cutting chatter. J Eng Ind 73(3):331–335

    Google Scholar 

  16. 16.

    Sims ND (2007) Vibration absorbers for chatter suppression: a new analytical tuning methodology. J Sound Vib 301(3–5):592–607

    Article  Google Scholar 

  17. 17.

    Elias S, Matsagar V (2017) Research developments in vibration control of structures using passive tuned mass dampers. Annu Rev Control 44:129–156

    Article  Google Scholar 

  18. 18.

    Yang Y, Wang Y, Liu Q (2018) Design of a milling cutter with large length–diameter ratio based on embedded passive damper. J Vib Control 25(3):506–516

    Article  Google Scholar 

  19. 19.

    Zuo L, Nayfeh SA (2005) The two-degree-of-freedom tuned-mass damper for suppression of single-mode vibration under random and harmonic excitation. ASME J Vib Acoust 128:56–65

    Article  Google Scholar 

  20. 20.

    Nakano Y, Takahara H, Kondo E (2013) Countermeasure against chatter in end milling operations using multiple dynamic absorbers. J Sound Vib 332:1626–1638

    Article  Google Scholar 

  21. 21.

    Ziegert JC, Stanislaus C, Schmitz TL, Sterling R (2006) Enhanced damping in long slender end mills. J Manuf Process 8(1):39–46

    Article  Google Scholar 

  22. 22.

    Kim NH, Won D, Ziegert JC (2006) Numerical analysis and parameter study of a mechanical damper for use in long slender endmills. Int J Mach Tools Manuf 46:500–507

    Article  Google Scholar 

  23. 23.

    Madoliat R, Hayati S, Ghasemi Ghalebahman A (2011) Investigation of chatter suppression in slender endmill via a frictional damper. Sci Iran 18(5):1069–1077

    Article  Google Scholar 

  24. 24.

    Senthilkumar M, Mohanasundaram KM, Sathishkumar B (2012) A case study on vibration control in a boring bar using particle damping. Int J Eng Sci Technol 3(8):177–184

    Google Scholar 

  25. 25.

    Biju CV, Shunmugam MS (2014) Investigation into effect of particle impact damping (PID) on surface topography in boring operation. Int J Adv Manuf Technol 75:1219–1231

    Article  Google Scholar 

  26. 26.

    Liu Y, Liu Z, Song Q, Wang B (2016) Development of constrained layer damping toolholder to improve chatter stability in end milling. Int J Mech Sci 117:299–308

    Article  Google Scholar 

  27. 27.

    Fu Q, Lorite GS, Rashid MM-U, Selkälä T, Uusitalo J, Toth G, Kordas K, Österlind T, Nicolescu CM (2015) Suppressing tool chatter with novel multi-layered nanostructures of carbon based composite coatings. J Mater Process Technol 223:292–298

    Article  Google Scholar 

  28. 28.

    Razak NH, Chen ZW, Pasang T (2016) Progression of tool deterioration and related cutting force during milling of 718Plus superalloy using cemented tungsten carbide tools. Int J Adv Manuf Technol 86:3203–3216

    Article  Google Scholar 

  29. 29.

    Möhring HC, Brecher C, Abele E, Fleischer J, Bleicher F (2015) Materials in machine tool structures. CIRP Ann 64:725–748

    Article  Google Scholar 

  30. 30.

    Turner S, Merdol D, Altintas Y, Ridgway K (2007) Modelling of the stability of variable helix end mills. Int J Mach Tools Manuf 47(9):1410–1416

    Article  Google Scholar 

  31. 31.

    Guo Y, Lin B, Wang WQ (2019) Optimization of variable helix cutter for improving chatter stability. Int J Adv Manuf Technol 104(5):2553–2565

    Article  Google Scholar 

  32. 32.

    Fazelinia H, Olgac N (2009) New perspective in process optimisation of variable pitch milling. Int J Mater Prod Technol 35(1–2):47–63

    Article  Google Scholar 

  33. 33.

    Otto A, Rauh S, Ihlenfeldt S, Radons G (2017) Stability of milling with non-uniform pitch and variable helix tools. Int J Adv Manuf Technol 89(9):2613–2625

    Article  Google Scholar 

  34. 34.

    Weaver JW, Timoshenko SP, Young DH (1990) Vibration problems in engineering, 5th Edition. John Wily & Sons Interscience, New York

    Google Scholar 

  35. 35.

    Yu Y, Chen L, Sun W, Zeng B, Sun Y (2018) An analytical investigation on large post-buckling behavior of a drilling shaft modeled as a rotating beam with various boundary conditions. Int J Mech Sci 148:486–495

    Article  Google Scholar 

  36. 36.

    Huang JL, Su RKL, Lee YY, Chen SH (2011) Nonlinear vibration of a curved beam under uniform base harmonic excitation with quadratic and cubic nonlinearities. J Sound Vib 330:5151–5164

    Article  Google Scholar 

  37. 37.

    Oberst H, Frankenfeld K (1952) Uber die dampfung der biegeschwingungen duner bleche durch fest haftendebelage. Acustica 2(4):181–194

    Google Scholar 

  38. 38.

    Lee DG, Hwang HY, Kim JK (2003) Design and manufacture of a carbon fiber epoxy rotating boring bar. Compos Struct 60:115–124

    Article  Google Scholar 

  39. 39.

    Schmitz TL, Smith KS (2009) Machining dynamics, frequency response to improved productivity. Springer, New York

    Google Scholar 

  40. 40.

    Zhang Z, Li HG, Meng G, Tu XT, Cheng CM (2016) Chatter detection in milling process based on the energy entropy of VMD and WPD. Int J Mach Tools Manuf 108:106–112

    Article  Google Scholar 

Download references


This work was funded by the National Natural Science Foundation of China (No.51975336), the Fundamental Research Funds of Shandong University (2017JC041), and Komatsu (Shan Dong) Construction Machinery Co., Ltd. In the meantime, the first author received support from China Scholarship Council.

Author information



Corresponding author

Correspondence to Yi Wan.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Xia, Y., Wan, Y., Luo, X. et al. Chatter suppression in large overhang face milling using a toolholder with high dynamic performance. Int J Adv Manuf Technol 108, 1713–1724 (2020).

Download citation


  • Face milling
  • Toolholder
  • Length-diameter ratio
  • Dynamic characteristic
  • Chatter suppression