Eddy Current-Based Vibration Suppression for Finish Machining of Assembly Interfaces of Large Aircraft Vertical Tail

Abstract

Assembly interface of aircraft vertical tail is a large thin-wall structure and made from titanium alloys, which causes easily machining vibration, deformation and undercutting in finish machining due to its low stiffness, low thermal conductivity, and high chemical activity. To address these problems, a novel eddy current damper for assembly interfaces machining (ECD-AIM) is proposed to suppress multimodal vibration in the machining of the assembly interfaces. Within the context, the mathematical model of damping performance of the damper is established based on the principle of electromagnetic induction, based on which a novel design of the damper is proposed, and optimized by considering the relationship between damping performance and the key components of the damper. Then, the dynamics model of the suppression system of the assembly interface machining is established, where the relationship between vibration velocity and damping performance of the damper is obtained by using numerical analysis and finite element simulation. Finally, the damping performance of the damper is validated in terms of the three configurations (no applied ECD-AIM, a single ECD-AIM, and dual ECD-AIMs) via a set of dynamic tests (impact tests and harmonic tests) and cutting tests. The test results demonstrate that the configuration of dual ECD-AIMs can guarantee stability and reliability of assembly interface machining. The proposed damper can provide a feasible solution for vibration suppression in a limited workspace.