Vibratory Analysis of Turning Process

2011 ◽  
Vol 70 ◽  
pp. 333-338
Author(s):  
Roger Serra
Keyword(s):  
Cutting Tool ◽  
Structural Parameters ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Turning Process ◽  
Complex Dynamic ◽  
Vibratory Analysis ◽  
Finite Element Calculations ◽  
Tool Vibrations ◽  
Lathe Tool

The aim of the paper is to analyse the vibrations during a turning manufacturing process in terms of the Machine-Tool-Part unit having particularly complex dynamic characteristics. The vibratory phenomenon is influenced by many parameters like workpiece, tool overhang, cutting speed, depth of cut and feed rate. This phenomenon is not completely known yet, so the aim was to highlight its origins using two complementary approaches: numerical and experimental. Finite element calculations were carried out, in order to identify parameters which characterize vibrations in machining like structural parameters (lathe, tool holder, cutting tool, workpiece, tailstock, tool overhang ...). A design for an experiment of process parameters (depth of cut, feed and cutting speed) was used and one series of turning tests was performed. Results have shown a significant effect between these parameters on the resulting surface roughness, consumed power, cutting time and tool vibrations and a best comprehension of the process.

Effect of Offset Distance on Cutting Forces and Heat Generation in Multi-Tool Turning Process

2014 ◽  
Vol 592-594 ◽  
pp. 211-215 ◽  
Author(s):  
R. Kalidasan ◽  
M. Yatin ◽  
D.K. Sarma ◽  
S. Senthilvelan
Keyword(s):  
Cutting Tool ◽  
Gray Cast Iron ◽  
Single Point ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Turning Process ◽  
Additional Tool ◽  
Offset Distance

Productivity enhancement assumes a paramount importance in today’s competitive industrial world. The aim of this work is to improve productivity in a conventional lathe with two single point cutting tools machining a workpiece simultaneously. An additional tool holding fixture is fabricated and integrated so that distance between the two cutting tools can be varied and has a provision to provide individual depth of cut. Experiments were performed on gray cast iron workpiece at different offset distances between the cutting tools, at a particular cutting speed, feed rate and depth of cut. In the multi-tool turning process, lagging rear cutting tool experiences lesser cutting force than leading front cutting tool. This behaviour is due to the machining of front cutting tool preheat as well as reduction of effective cutting speed while machining with rear cutting tool. With increase in offset distance, moment acting on the work piece contributes to increase in resistance against machining and hence front tool experiences higher force than rear cutting tool.

Application of Taguchi Method for Optimization of Parameters in Turning Operation

2016 ◽  
Vol 16 (3) ◽  
pp. 183-187 ◽  
Author(s):  
B. Singaravel ◽  
T. Selvaraj
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Optimum Level ◽  
Turning Process ◽  
Tool Vibration ◽  
Machining Characteristics

AbstractCutting tool vibration analysis is the effective way to understand the machining characteristics of any material. In the present work, the effect of process parameters on cutting tool vibration is estimated using Taguchi method in turning of EN25 steel. Taguchi method uses Signal-to-Noise ratio (S/N) and Analysis of Variance (ANOVA) to determine the optimum level of process parameters and significant parameters. The results showed that cutting speed of 215 m/min, feed rate of 0.07 mm/rev and depth of cut of 0.5 mm are the optimum combination of process parameters. Cutting speed and depth of cut are the influencing parameters on cutting tool vibration. The results are experimentally verified and the results based on turning process response can be effectively improved.

Deep Hole Machining with a Small Diameter Drill and Ultrasonic Vibration

2017 ◽  
Vol 749 ◽  
pp. 107-110
Author(s):  
Yuta Masu ◽  
Tomohito Fukao ◽  
Taiga Yasuki ◽  
Masahiro Hagino ◽  
Takashi Inoue
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Small Diameter ◽  
Maximum Amplitude ◽  
Depth Of Cut ◽  
Deep Hole ◽  
Work Material ◽  
Finished Surface

The method of imparting ultrasonic vibration to the cutting tool is known to improve the shape accuracy and finished surface roughness. However, a uniform evaluation of this function in drilling has not been achieved, and the cutting process cannot be checked from the outside. The aim of this study is to investigate the cutting characteristics in deep hole drilling when an ultrasonic vibrator on the table of a machining center provides vibration with a frequency of 20 kHz to the work piece. The ultrasonic vibrations in this system reach the maximum amplitude in the center of the work material. We evaluated the change in finished surface roughness between the section where drilling starts to the point of maximum amplitude with ultrasonic vibration. The main cutting conditions are as follows: cutting speed (V) 12.6 (mm/min); feed rate (s) 30, 60 (mm/rev); depth of cut (t) = 32 (mm); work material, tool steel; cutting tool material, HSS; point angle (σ) 118 (°); and drill diameter (φ) 4 (mm). Lubricant powder was also added to clarify the cutting effect, and compared the condition in which there was no ultrasonic vibration. The results showed that surface roughness at the point of maximum amplitude was better than that with no vibration.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Cutting Tool Temperatures in Contour Turning: Transient Analysis and Experimental Verification

1997 ◽  
Vol 119 (4A) ◽  
pp. 494-501 ◽  
Author(s):  
D. A. Stephenson ◽  
T.-C. Jen ◽  
A. S. Lavine
Keyword(s):  
Transient Analysis ◽  
Cutting Tool ◽  
Process Development ◽  
Thermal Contact ◽  
Model Development ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Transient Conditions ◽  
Trouble Shooting ◽  
Model Predictions

This paper describes a model for predicting cutting tool temperatures under transient conditions. It is applicable to processes such as contour turning, in which the cutting speed, feed rate, and depth of cut may vary continuously with time. The model is intended for use in process development and trouble shooting. Therefore, emphasis is given in the model development to enable rapid computation and to avoid the need to specify parameters such as thermal contact resistances and convection coefficients which are not known in practice. Experiments were conducted to validate the predictive model. The model predictions with two different boundary conditions bound the experimental results. An example is presented which shows the utility of the model for process planning.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Low Cost Vibration Measurement and Optimization during Turning Process

2018 ◽  
Vol 1148 ◽  
pp. 103-108 ◽  
Author(s):  
N.V.S. Shankar ◽  
A. Gopi Chand ◽  
K. Hanumantha Rao ◽  
K. Prem Sai
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Low Cost ◽  
Machining Process ◽  
Vibration Measurement ◽  
Depth Of Cut ◽  
Turning Process ◽  
Taguchi Analysis ◽  
Series Of Experiments

During machining any material, vibrations play a major role in deciding the life of the cutting tool as well as machine tool. The magnitude acceleration of vibrations is directly proportional to the cutting forces. In other words, if we are able to measure the acceleration experienced by the tool during machining, we can get a sense of force. There are many commercially available, pre-calibrated accelerometer sensors available off the shelf. In the current work, an attempt has been made to measure vibrations using ADXL335 accelerometer. This accelerometer is interfaced to computer using Arduino. The measured values are then used to optimize the machining process. Experiments are performed on Brass. During machining, it is better to have lower acceleration values. Thus, the first objective of the work is to minimize the vibrations. Surface roughness is another major factor which criterion “lower is the better” applies. In order to optimize the values, a series of experiments are conducted with three factors, namely, tool type (2 levels), Depth of cut (3 levels) and Feed are considered (3 levels). Mixed level optimization is performed using Taguchi analysis with L18 orthogonal array. Detailed discussion of the parameters shall be given in the article.

Grey-Based Taguchi Analysis Approach for Optimization of Multi-Objective Problem

2014 ◽  
pp. 219-239
Author(s):  
Nirmal S Kalsi ◽  
Rakesh Sehgal ◽  
Vishal S. Sharma
Keyword(s):  
Feed Rate ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Multi Objective ◽  
Analysis Technique ◽  
Grey Relation

Due to the increase in complexity and expectations of more reliable solutions for a problem, the importance of multi-objective problem solutions is increasing day by day. It can play a significant role in making a decision. In the present approach, many combinations of the optimization techniques are proposed by the researchers. These hybrid evolutionary methods integrate positive characteristics of different methods and show the advantage to reach global optimization. In this chapter, Taguchi method and the GRA (Grey Relation Analysis) technique are pronounced and used to optimize a multi-objective metal cutting process to yield maximum performance of tungsten carbide-cobalt cutting tool inserts in turning. L18 orthogonal array is selected to analyze the effect of cutting speed, feed rate, and depth of cut using cryogenically treated and untreated inserts. The performance is evaluated in terms of main cutting force, power consumption, tool wear, and material removal rate using main effect plots of S/N (Signal to Noise) ratios. This chapter indicates that the grey-based Taguchi technique is not only a novel, efficient, and reliable method of optimization, but also contributes to satisfactory solution for multi-machining objectives in the turning process. It is concluded that cryogenically treated cutting tool inserts perform better. However, the feed rate affects the process performance most significantly.

scholarly journals Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2998 ◽  
Author(s):  
Kubilay Aslantas ◽  
Mohd Danish ◽  
Ahmet Hasçelik ◽  
Mozammel Mia ◽  
Munish Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Removal Rate ◽  
Cutting Speed ◽  
Small Diameter ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Depth Of Cut ◽  
Turning Process ◽  
Micro Turning

Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

Sign in / Sign up

Export Citation Format

Share Document