Design of a slender turning cutting tool via a vibration absorber equipped with piezoelectric ceramic

Turning cutting tool with large length–diameter ratio has been essential when machining structural part with deep cavity and in-depth hole features. However, chatter vibration is apt to occur with the increase of tool overhang. A slender turning cutting tool with a length–diameter ratio of 7 is developed by using a vibration absorber equipped with piezoelectric ceramic. The vibration absorber has dual functions of vibration transfer to the absorber mass and vibration conversion to the electrical energy via the piezoelectric effect. Equations of motion are established considering the dual damping from the piezoelectric ceramic and rubber gasket. The equivalent damping of piezoelectric ceramic is derived, and the geometries are optimized to achieve optimal vibration suppression. The modal analysis demonstrates that the cutting tool with the vibration absorber can reach 80.1% magnitude reduction. Machining tests are carried out in the end. The machining acceleration and machined surface roughness validate the vibration suppression of the VA, and the output voltage by the piezoelectric ceramic demonstrates the ability of vibration sensing.

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Design of a turning cutting tool with large length–diameter ratio based on three-element type vibration absorber

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405419900433 ◽

2020 ◽

Vol 234 (6-7) ◽

pp. 1032-1043

Author(s):

Yiqing Yang ◽

Haoyang Gao ◽

Wenshuo Ma ◽

Qiang Liu

Keyword(s):

Frequency Response ◽

Cutting Tool ◽

Vibration Suppression ◽

Diameter Ratio ◽

Vibration Absorber ◽

Vibration Absorbers ◽

Target Mode ◽

Large Length ◽

Element Type ◽

Structural Parts

The vibration absorber has been effective in vibration control. From the demand of manufacturing structural parts with a deep hole, the design of a turning cutting tool with large length–diameter ratio is presented. An analytical approach of acquiring frequency response of primary structure equipped with typical single-degree-of-freedom vibration absorbers is formulated, and background modes are incorporated with the purpose of achieving an accurate tuning of vibration absorber. Specifically, the three-element type is investigated as the damping element of the vibration absorber embedded in the cutting tool contributes to the stiffness, although it demonstrates medium performance of vibration suppression according to non-dimensional analysis. The experimentally tuned frequency response function of the turning cutting tool with three-element vibration absorber achieves 87.1% reduction on the amplitude of the target mode. Finally, several configurations of internal turning operations are carried out to validate the design of the vibration absorber.

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Design of a milling cutter with large length–diameter ratio based on embedded passive damper

Journal of Vibration and Control ◽

10.1177/1077546318786594 ◽

2018 ◽

Vol 25 (3) ◽

pp. 506-516 ◽

Cited By ~ 12

Author(s):

Yiqing Yang ◽

Yunfei Wang ◽

Qiang Liu

Keyword(s):

High Speed ◽

Vibration Suppression ◽

Diameter Ratio ◽

Design Parameters ◽

Machined Surface ◽

Milling Cutter ◽

Passive Damper ◽

Machined Surface Roughness ◽

Large Length ◽

Low Mass Ratio

A milling cutter with large length–diameter ratio has been essential in machining structural parts with deep cavity and deep hole features. However, chatter vibration is apt to occur with the increase of tool overhang. A damped milling cutter is developed by employing a single-degree-of-freedom passive damper located inside the arbor. The stiffness and damping design of the embedded damper are carried out by following the equal peaks criterion. A novel design is fulfilled to avoid the disequilibrium of the cutter during high-speed rotation, and an accurate experimental tuning of the design parameters is required to achieve the optimum vibration suppression due to a low mass ratio of 2.5%. Modal analysis demonstrates that the damped cutter with an approximate length–diameter ratio of 8 can reach 75% magnitude reduction at all orientations, which is benefical to resist milling force excitation varying with the rotation angle. Chatter stability simulation demonstrates that the damped cutter is able to increase the stability limits based on the evaluation of undamped and Sandvik cutters. Three configurations of machining tests are carried out and the design of the damped cutter is validated by the machining audio signals and machined surface roughness in the end.

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Machined Surface Roughness Geometry Model Development on Ultrasonic Vibration Assisted Micromilling with End Mill

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.846.122 ◽

2020 ◽

Vol 846 ◽

pp. 122-127

Author(s):

Gandjar Kiswanto ◽

Yolanda Rudy Johan ◽

Poly ◽

Tae Jo Ko

Keyword(s):

Surface Roughness ◽

Ultrasonic Vibration ◽

Cutting Tool ◽

Model Development ◽

Cutting Edge ◽

End Mill ◽

Machined Surface ◽

Workpiece Surface ◽

Geometry Model ◽

Machined Surface Roughness

Micro products or micro components are commonly used in today’s world. Research around micromanufacture technologies to produce a better product quality has been going on extensively. Ultrasonic vibration assisted micromilling (UVAM) is one of the technologies that can give a better machining qualities over the conventional ones. One of the benefits UVAM can give is reducing the machined surface roughness. The purpose of this paper is to give an idea how vibration assisted micromilling can give a better surface roughness quality. The theoritical surface roughness geometry model is made using MATLAB software. The cutting tool used in the simulation is end mill. There is a feature of the cutting tool called bottom cutting edge angle. This feature will be considered on this paper. The effects of the bottom cutting edge on workpiece machined surface can be looked visually from the simulation. Thus, the effects of cutting process using UVAM on the workpiece surface can be looked as well through the simulation.

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Vibration Suppression of a Linear Oscillator Force-Excited by Random Excitation via an Inerter Pendulum Vibration Absorber

10.1115/detc2021-71674 ◽

2021 ◽

Author(s):

Joel A. Cosner ◽

Wei-Che Tai

Keyword(s):

Vibration Suppression ◽

Equations Of Motion ◽

Qualitative Change ◽

Random Excitation ◽

Vibration Absorber ◽

Single Degree Of Freedom ◽

Nonlinear Energy Transfer ◽

Mass Damper ◽

The Time Domain ◽

Insight Into

Abstract In this theoretical study, the vibration suppression and nonlinear energy transfer, as a function of a dimensionless pendulum length parameter, is investigated for an Inerter Pendulum Vibration Absorber (IPVA) attached to a linear single-degree-of-freedom spring-mass-damper system, subject to white noise excitation. Stochastic differential equations of motion are first developed and integrated to determine the evolution of the response and associated mean and mean square values for long integration times. Dynamic statistical moment equations are then developed, while arc-length continuation is used to track stationary the moments as a function of the pendulum length. Two noise intensity and damping configurations are analyzed and a critical parameter value, in both cases, is found to produce a qualitative change in the system dynamics accompanied by optimal vibration suppression. The results are compared to the response of a linear system without an IPVA to quantify the vibration suppression. Realizations in the time domain are finally calculated to provide validation for the results and gain insight into the changing dynamics of the system as a function of the pendulum length, leading to the discovery of intermittent rotation for sufficiently large pendulum length.

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The Effect of the Cutting Parameters on the Machined Surface Roughness

Solid State Phenomena ◽

10.4028/www.scientific.net/ssp.260.219 ◽

2017 ◽

Vol 260 ◽

pp. 219-226 ◽

Cited By ~ 1

Author(s):

Viktors Gutakovskis ◽

Eriks Gerins ◽

Janis Rudzitis ◽

Artis Kromanis

Keyword(s):

Surface Roughness ◽

Metal Cutting ◽

Cutting Tool ◽

Cutting Tools ◽

Cutting Parameters ◽

Cutting Process ◽

Tool Geometry ◽

Machining Parameters ◽

Machined Surface ◽

Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

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Parameter Optimization of Milling Ti6Al4V Using GA Approach

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.426-427.1 ◽

2010 ◽

Vol 426-427 ◽

pp. 1-4 ◽

Cited By ~ 2

Author(s):

Feng Xu ◽

Jian Jun Zhu ◽

Xin Wu ◽

Xiao Jun Zang ◽

Dun Wen Zuo

Keyword(s):

Genetic Algorithm ◽

Titanium Alloy ◽

Parameter Optimization ◽

Cutting Tool ◽

Metal Removal ◽

Removal Rate ◽

Metal Removal Rate ◽

Machined Surface ◽

Milling Parameters ◽

Machined Surface Roughness

The research was carried out on the parameter optimization of milling titanium alloy in this paper. The cutting models including cutting force, tool life and machined surface roughness are obtained by orthogonal array experiments. The maximum metal removal rate, MRR is selected as objective function. The constraints related to machine tool, workpiece, cutting tool and other machining situations are presented in details. Genetic algorithm is used to search for the optimum milling parameters for the maximum metal removal rate of titanium alloy. The optimization results show the optimization system can improve the productivity of milling Ti6Al4V obviously.

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PHYSICAL PRINCIPLES OF VIBRATION CUTTING IN TURNING

Bulletin of Belgorod State Technological University named after V G Shukhov ◽

10.12737/24626 ◽

2017 ◽

Vol 2 (3) ◽

pp. 94-102

Author(s):

Макаров ◽

Aleksey Makarov ◽

Владимиров ◽

Aleksandr Vladimirov ◽

Сергиев ◽

...

Keyword(s):

Cutting Tool ◽

Physical Processes ◽

Machined Surface ◽

Hard Materials ◽

Cutting Vibration ◽

Edge Wear ◽

Machined Surface Roughness ◽

Cutting Zone ◽

Physical Principles ◽

Selection Of

The vibrating cutting is one of the effective methods of processing workpieces of hard materials for the manufacture of parts of mining and metallurgical equipment. With proper selection of the vibration modes of cutting improves durability of the cutting tool and to ensure reliable chip control. When machining materials using a cutting tool vibration in the cutting area there are processes other than the processes occurring in the normal turning. A brief literature review of studies describing the processes occurring in the cutting zone. Particular attention is paid to the process and built-up edge is a schematic diagram of its occurrence and the removal from the surface of the cutting tool. The mechanism of the cutting edge wear, impact durability during the built-up edge on the tool and the machined surface roughness. A hypothesis to explain the physical processes of cutting vibration during turning. A scheme of the process of cutting vibration and formulated conditions for the formation of build-up and its subsequent removal from the tool tip.

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Some Aspects of Improving Integrity of Machined Surfaces on Al/SiCp Metal Matrix Composites

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.596 ◽

2010 ◽

Vol 443 ◽

pp. 596-601 ◽

Cited By ~ 4

Author(s):

Uday A. Dabade ◽

Suhas S. Joshi

Keyword(s):

Surface Roughness ◽

Residual Stresses ◽

Surface Integrity ◽

Experimental Work ◽

Metal Matrix ◽

Cutting Tool ◽

Matrix Composites ◽

Machined Surface ◽

Machined Surface Roughness ◽

Machined Surfaces

This paper presents findings of an experimental work which involved use of wiping edge on the cutting tool and a priory heating of the work surfaces to improve the integrity of machined surfaces. The wiper edge cleans the machined surface and a priory heating induces necessary local ductility into the machined surface to promote improvement in the surface integrity. The result shows that the wiper inserts reduce surface roughness (by about 38%); cutting forces (by about 8%) and induce compressive (or lower tensile) residual stresses in the machined surfaces, hence help to improve the surface integrity. Similarly, a priory heating of work surfaces at 70°C was also found to improve machined surface roughness considerably.

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Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

International Journal of Engineering and Advanced Technology - Regular Issue ◽

10.35940/ijeat.a2231.129219 ◽

2019 ◽

Vol 9 (2) ◽

pp. 109-113

Keyword(s):

Surface Roughness ◽

Aluminum Alloy ◽

Tool Life ◽

Feed Rate ◽

Cutting Tool ◽

Cutting Speed ◽

Machining Parameters ◽

Machined Surface ◽

Machined Surface Roughness ◽

Aluminum Alloy 7075

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.

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