Integration of Lattice Structures into the Boring Bars as a Passive Chatter Suppression Technique: Concepualization, Modelling and Simulation

The present study concentrates on passive damping technology, in which the damping of vibrations is accomplished by the integration of lattice structures into the boring bar. To complete this process, several steps must be followed. First, the largest possible hollow space within the boring bar was determined, and the two main influencing factors—stiffness and natural frequency—were harmonized. A rigorous analysis of vibration reduction was conducted on the basis of a validated simulation model. This analysis involved six distinct lattice structures designed using ANSYS SpaceClaim 19.0. In light of the findings, a specialized, application-specific CAD simulation tool was developed, employing appropriate methodologies to circumvent the limitations of conventional CAD software. For the hollow integrated into the boring bar, ellipsoidal shapes were shown to be preferable to cylindrical ones due to their superior dynamic performance. The initial lattice structure, namely a cube lattice with side cross supports, exhibited an enhancement in damping of 55.58% in comparison with the reference model. Following this result, five additional modelling steps were performed, leading to an optimal outcome with a 67.79% reduction in vibrations. Moreover, the modifications made to the beam diameter of the lattice units yielded enhanced dynamic performance, as evidenced by a vibration suppression of 69.81%. The implementation of complex modelling steps, such as the integration of a hollow and the integration of lattice structures, could be successfully achieved through the development of a suitable and user-friendly simulation tool. The effectiveness of the simulation tool in enabling parameterized modelling for scalable lattice structures was demonstrated. This approach was found to be expeditious in terms of the time required for implementation. The potential exists for the extension of this simulation tool, with the objective of facilitating research projects with a view to optimization, i.e., a large number of research projects.