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HomeDefect and Diffusion ForumDefect and Diffusion Forum Vol. 450Scaling Methodology for Large Boring Bars with...

Scaling Methodology for Large Boring Bars with Tuned Mass Dampers

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Abstract:

Sectors such as energy, aerospace, and heavy machinery increasingly rely on the machining of large components, where boring bars can easily exceed 200 mm in diameter and reach length-to-diameter ratios of up to 14. In these operations, chatter remains the dominant limitation due to the inherently low dynamic stiffness of such long tools. While Tuned Mass Dampers (TMDs) are widely applied in small and medium-sized boring bars, but transferring this technology to large-scale tools introduces significant challenges, particularly in the selection and tuning of damper components and the difficulty of evaluating performance prior to manufacturing. Because producing large boring bars is costly, a structured and predictive design strategy is essential to avoid trial-and-error iterations. This work introduces a scaling methodology that adapts TMD-integrated boring bar designs to large dimensions, providing a systematic approach to predict dynamic behavior across different tool sizes. The methodology is demonstrated through a case study involving Ø200 mm boring bar with length of 14 times the diameter. Experimental validation with the manufactured prototype confirms that the proposed scaling strategy enables effective chatter suppression and offers a practical path for extending TMD technology to large-scale boring applications.

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Machining, Cutting and Severe Plastic Deformation Processes

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Periodical:

Defect and Diffusion Forum (Volume 450)

Pages:

71-81

DOI:

https://doi.org/10.4028/p-wko6TW

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Online since:

April 2026

Authors:

Mikel Etxebeste*, Iñaki M. Arrieta, Gorka Ortiz de Zarate, Pedro José Arrazola

Keywords:

Boring, Chatter, FEM, Machining, Modeling, Tuned Mass Damper (TMD)

Funder:

The publication of this article was funded by the Mondragon Goi Eskola Politeknikoa, J.M.A. S.Coop

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* - Corresponding Author

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