Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year.
This document presents a new analytical method for identifying stability lobes in high-speed machining of thin ribs. It describes developing a stability lobe diagram that shows the relationship between axial depth of cut and spindle speed, with lobe number as a parameter. The method involves using experimental modal analysis to determine dynamic characteristics of the machine-tool system and then using mathematical equations to simulate the real and imaginary parts of the frequency response function. This allows predicting stable and unstable machining regions. The document outlines the specific steps of the proposed method and shows examples of simulating the frequency response function and stability lobes using Mathcad software. It concludes that the method can predict stability lobes considering workpiece flexibility and that future work will incorporate experimental validation.
PREDICTION AND CONTROL OF LATHE MACHINE TOOL VIBRATION BY USING PASSIVE DAMPING ijiert bestjournal
In machining operation,the quality of surface finish is an important requirement for many turned work- pieces. Thus the choice of optimized cutting parameters is very important for controlling the required surface quality. The focus of present experimental study is to opt imize the cutting parameters using two performance measures,machine tool vibration and work-piece surface roughness The prediction and control of vibration between the tool and work piece is important as guidel ine to the machine tools user for an optimal selection of depth of cut,cutting speed,tool feed rate to minimize the vibration. In machining operation there are different variables deleterious the desire d result. In this process the behavior of machine tool,cutting tool life and cutting tool vibration are the complex pheno menon which influences on the dimensional precision of the components to be machined,the cutting tool vibrations are mainly influenced by cutting parameters like cutting speed,depth of cut and tool feed rate. In this project work,CNC lathe cutting tool vibrations are controlled the tool holder is supported wit h and without damping pad. To increase the accuracy of experiments,Taguchi L9 experimental design me thod has used in this experiment. Experimental result are validate with analysis of variance (ANOVA) and regression analysis to identify the influences of the different cutting parameter on the vibra tion of cutting tool.
A Comparison of Optimization Methods in Cutting Parameters Using Non-dominate...Waqas Tariq
Since cutting conditions have an influence on reducing the production cost and time and deciding the quality of a final product the determination of optimal cutting parameters such as cutting speed, feed rate, depth of cut and tool geometry is one of vital modules in process planning of metal parts. With use of experimental results and subsequently, with exploitation of main effects plot, importance of each parameter is studied. In this investigation these parameters was considered as input in order to optimized the surface finish and tool life criteria, two conflicting objectives, as the process performance simultaneously. In this study, micro genetic algorithm (MGA) and Non-dominated Sorting Genetic Algorithm (NSGA-II) were compared with each other proving the superiority of Non-dominated Sorting Genetic Algorithm over micro genetic since Non-dominated Sorting Genetic Algorithm results were more satisfactory than micro genetic algorithm in terms of optimizing machining parameters.
Prediction of surface roughness in high speed machining a comparisoneSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
In this paper the objective of this work is to develop a model to simulate the vibrational
effects of rotating machine parts on the single point cutting tool and cutting force acting on single
point cutting tool in turning. In this paper experimental studies were performed on turning process &
vibration is measured with the help of accelerometer along with a device called as Fast Fourier
Transformer (FFT) Analyzer and cutting force is measured with the help of Tool dynamometer. The
vibration of single point cutting tool is sensed by accelerometer located on the tool-post of lathe
machine. The accelerometer will send the sensed vibration to FFT Analyzer which can be convert the
sensed data by using accelerometer shown in PC such as frequency, Amplitude, displacement & so
on and cutting force is sensed by strain gauges which are compacted in tool post. The sensed force
will send to dynamometer, it displays the cutting force. The obtained experimental data given to an
Artificial Neural Network (ANN) in Matlab, with the help of experimental data ANN is to be trained.
And by using ANN can predict the vibrations and cutting force by changing parameters of turning
such as spindle speed, feed & depth of cut. This model of ANN can be predict vibrations of single
point cutting tool and cutting force acting on single point cutting tool to avoid the failure of cutting
tool.
PREDICTION AND CONTROL OF LATHE MACHINE TOOL VIBRATION BY USING PASSIVE DAMPING ijiert bestjournal
In machining operation,the quality of surface finish is an important requirement for many turned work- pieces. Thus the choice of optimized cutting parameters is very important for controlling the required surface quality. The focus of present experimental study is to opt imize the cutting parameters using two performance measures,machine tool vibration and work-piece surface roughness The prediction and control of vibration between the tool and work piece is important as guidel ine to the machine tools user for an optimal selection of depth of cut,cutting speed,tool feed rate to minimize the vibration. In machining operation there are different variables deleterious the desire d result. In this process the behavior of machine tool,cutting tool life and cutting tool vibration are the complex pheno menon which influences on the dimensional precision of the components to be machined,the cutting tool vibrations are mainly influenced by cutting parameters like cutting speed,depth of cut and tool feed rate. In this project work,CNC lathe cutting tool vibrations are controlled the tool holder is supported wit h and without damping pad. To increase the accuracy of experiments,Taguchi L9 experimental design me thod has used in this experiment. Experimental result are validate with analysis of variance (ANOVA) and regression analysis to identify the influences of the different cutting parameter on the vibra tion of cutting tool.
A Comparison of Optimization Methods in Cutting Parameters Using Non-dominate...Waqas Tariq
Since cutting conditions have an influence on reducing the production cost and time and deciding the quality of a final product the determination of optimal cutting parameters such as cutting speed, feed rate, depth of cut and tool geometry is one of vital modules in process planning of metal parts. With use of experimental results and subsequently, with exploitation of main effects plot, importance of each parameter is studied. In this investigation these parameters was considered as input in order to optimized the surface finish and tool life criteria, two conflicting objectives, as the process performance simultaneously. In this study, micro genetic algorithm (MGA) and Non-dominated Sorting Genetic Algorithm (NSGA-II) were compared with each other proving the superiority of Non-dominated Sorting Genetic Algorithm over micro genetic since Non-dominated Sorting Genetic Algorithm results were more satisfactory than micro genetic algorithm in terms of optimizing machining parameters.
Prediction of surface roughness in high speed machining a comparisoneSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
In this paper the objective of this work is to develop a model to simulate the vibrational
effects of rotating machine parts on the single point cutting tool and cutting force acting on single
point cutting tool in turning. In this paper experimental studies were performed on turning process &
vibration is measured with the help of accelerometer along with a device called as Fast Fourier
Transformer (FFT) Analyzer and cutting force is measured with the help of Tool dynamometer. The
vibration of single point cutting tool is sensed by accelerometer located on the tool-post of lathe
machine. The accelerometer will send the sensed vibration to FFT Analyzer which can be convert the
sensed data by using accelerometer shown in PC such as frequency, Amplitude, displacement & so
on and cutting force is sensed by strain gauges which are compacted in tool post. The sensed force
will send to dynamometer, it displays the cutting force. The obtained experimental data given to an
Artificial Neural Network (ANN) in Matlab, with the help of experimental data ANN is to be trained.
And by using ANN can predict the vibrations and cutting force by changing parameters of turning
such as spindle speed, feed & depth of cut. This model of ANN can be predict vibrations of single
point cutting tool and cutting force acting on single point cutting tool to avoid the failure of cutting
tool.
Machining of duplex stainless steels: a comparative studyRasper Dellshad
This paper investigates the machining of super duplex EN 1.4410, standard duplex EN 1.4462 and austenitic EN 1.4404 stainless steels through a two-phase experimental study. In the first phase, a new methodology based on Mamdani fuzzy interference of classified chip shapes in chip breaking charts to predict the chip volume ratio is presented. Chip volume ratios, specific cutting pressures, cutting powers and resultant cutting forces are considered as performance characteristics and converted into single indices using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), Grey Relational Analysis (GRA), VIKOR method and Utility Analysis (UA). An expert system based on fuzzy rule modelling approach is then adopted to combine the computed indices into a single Universal Characteristics Index (UCI). Results showed that converting the output of different Multiple Attribute Decision Making (MADM) methods into a single UCI index is a simple and efficient technique in determining an optimal combination of the cutting parameters. Constrained simulated annealing optimization procedure is then employed to evaluate the optimal process parameters thereby satisfying conflicting requirements of each of performance factors. First ranking UCI values are analyzed and compared with the output of multi-objective optimization techniques (MOO) using Weighted Sum Method. A remarkable improve in reduction of cutting power consumption, specific cutting pressure, resultant cutting forces are reported when first rank UCI value is directly reported as optimum point instead of performing conventional optimization. In the second phase, cutting force and machine current consumption signals are adopted as indirect cutting tool wear monitoring techniques to graph the tool wear progression. Results showed that the tool life strongly affected by cutting speed and workpiece material.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
Parametric Study of Multi-Spot Welded Lap Shear Specimen for Shear StrengthIJERA Editor
The effect of number of spots, spot spacing, squeezing force, welding current, weld time , overlapping length
and sheet thicknesson the shear strength of two similar galvanized steel sheets are investigated through
experiments using RSM method. Similar sheets of galvanized steel sheets are made by resistance spot welding
at different processing conditions and these joint populations were tested under lap-shear loading conditions.
Specially fabricated fixture is used to load the lap shear specimen in the universal testing machine Regression
analysis is done to obtain relationship between shear strength and selected parameters. The experimental results
indicate that the failure loads of spot welds in lap-shear specimens increase when number of spot, squeezing
force, welding current and sheet thickness increase for the given ranges.
Finite Element Analysis of Damping Performance of VEM Materials Using CLD Tec...IJERA Editor
Most engineering structures experiences vibrational motion, this unwanted vibrations can result in premature
structural failure. Many methods are developed which enhances capability of damping such as constrained layer
damping. Shear motion is produced in VEM due to constraining layer to resist unwanted vibrational energy.
This paper shows theeffect of varying the thickness of viscoelastic materials on damping performance of CLD
beam.The damping performance is measured in terms of modal loss factor.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Evaluation The Effect Of Machining Parameters For MRR Using Turning Of Alumin...IJSRD
Turning is a basic operation for various industries & it is very essential to optimize the various parameters affecting turning for the optimum condition. Turning operation is affected by both machining parameters & Cutting fluids. The parameter influence most are cutting speed, depth of cut , feed, geometry of cutting tool like principle cutting edge angle ,rake angle, nose radius etc. In order to control MRR it is very necessary to control these parameters. In the project turning operation the different values of cutting parameters, cutting speed (45, 90,140,330), feed rate (.1, 22, 44, 68 mm/rev), depth of cut (.5, 1, 1.5,2 mm) are selected. MRR is largely influenced by Speed then Feed then DOC. MRR shows an increasing trend with increasing Speed. MRR shows an increasing trend with increasing Feed. MRR shows an increasing trend with increasing DOC.
Machining of duplex stainless steels: a comparative studyRasper Dellshad
This paper investigates the machining of super duplex EN 1.4410, standard duplex EN 1.4462 and austenitic EN 1.4404 stainless steels through a two-phase experimental study. In the first phase, a new methodology based on Mamdani fuzzy interference of classified chip shapes in chip breaking charts to predict the chip volume ratio is presented. Chip volume ratios, specific cutting pressures, cutting powers and resultant cutting forces are considered as performance characteristics and converted into single indices using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), Grey Relational Analysis (GRA), VIKOR method and Utility Analysis (UA). An expert system based on fuzzy rule modelling approach is then adopted to combine the computed indices into a single Universal Characteristics Index (UCI). Results showed that converting the output of different Multiple Attribute Decision Making (MADM) methods into a single UCI index is a simple and efficient technique in determining an optimal combination of the cutting parameters. Constrained simulated annealing optimization procedure is then employed to evaluate the optimal process parameters thereby satisfying conflicting requirements of each of performance factors. First ranking UCI values are analyzed and compared with the output of multi-objective optimization techniques (MOO) using Weighted Sum Method. A remarkable improve in reduction of cutting power consumption, specific cutting pressure, resultant cutting forces are reported when first rank UCI value is directly reported as optimum point instead of performing conventional optimization. In the second phase, cutting force and machine current consumption signals are adopted as indirect cutting tool wear monitoring techniques to graph the tool wear progression. Results showed that the tool life strongly affected by cutting speed and workpiece material.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
Parametric Study of Multi-Spot Welded Lap Shear Specimen for Shear StrengthIJERA Editor
The effect of number of spots, spot spacing, squeezing force, welding current, weld time , overlapping length
and sheet thicknesson the shear strength of two similar galvanized steel sheets are investigated through
experiments using RSM method. Similar sheets of galvanized steel sheets are made by resistance spot welding
at different processing conditions and these joint populations were tested under lap-shear loading conditions.
Specially fabricated fixture is used to load the lap shear specimen in the universal testing machine Regression
analysis is done to obtain relationship between shear strength and selected parameters. The experimental results
indicate that the failure loads of spot welds in lap-shear specimens increase when number of spot, squeezing
force, welding current and sheet thickness increase for the given ranges.
Finite Element Analysis of Damping Performance of VEM Materials Using CLD Tec...IJERA Editor
Most engineering structures experiences vibrational motion, this unwanted vibrations can result in premature
structural failure. Many methods are developed which enhances capability of damping such as constrained layer
damping. Shear motion is produced in VEM due to constraining layer to resist unwanted vibrational energy.
This paper shows theeffect of varying the thickness of viscoelastic materials on damping performance of CLD
beam.The damping performance is measured in terms of modal loss factor.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Similar to Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year.
Evaluation The Effect Of Machining Parameters For MRR Using Turning Of Alumin...IJSRD
Turning is a basic operation for various industries & it is very essential to optimize the various parameters affecting turning for the optimum condition. Turning operation is affected by both machining parameters & Cutting fluids. The parameter influence most are cutting speed, depth of cut , feed, geometry of cutting tool like principle cutting edge angle ,rake angle, nose radius etc. In order to control MRR it is very necessary to control these parameters. In the project turning operation the different values of cutting parameters, cutting speed (45, 90,140,330), feed rate (.1, 22, 44, 68 mm/rev), depth of cut (.5, 1, 1.5,2 mm) are selected. MRR is largely influenced by Speed then Feed then DOC. MRR shows an increasing trend with increasing Speed. MRR shows an increasing trend with increasing Feed. MRR shows an increasing trend with increasing DOC.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Experimental Investigation of Effect of Tool Length on Surface Roughness duri...IOSR Journals
: In the turning operation, vibration is a frequent problem, which affects the result of the machining
and in particular the surface finish. Tool life is also influenced by vibrations. Severe acoustic noise in the
working environment frequently results as a dynamic motion between the cutting tool and the work piece. In all
cutting operations like turning, boring and milling vibrations are induced due to deformation of the work piece.
In the turning process, the importance of machining parameter choice is increased, as it controls the surface
quality required. Tool overhang is a cutting tool parameter that has not been investigated in as much detail as
some of the better known ones. It is appropriate to keep the tool overhang as short as possible; however, a
longer tool overhang may be required depending on the geometry of the work piece and when using the holeturning
process in particular. In this study, we investigate the effects of changes in the tool overhang in the
external turning process on both the surface quality of the work piece and tool wear. For this purpose, we used
work pieces of AISI 1050 material with diameters of 20, 30, and 40 mm; and the surface roughness of the work
piece were determined through experiments using constant cutting speed and feed rates with different depth of
cuts (DOCs) and tool overhangs. We observed that the effect of the DOC on the surface roughness is negligible,
but tool overhang is more important. The deflection of the cutting tool increases with tool overhang. Two
different analytical methods were compared to determine the dependence of tool deflection on the tool
overhang. Also, the real tool deflection values were determined using a comparator. We observed that the tool
deflection values were quite compatible with the tool deflection results obtained using the second analytical
method.
Modeling and Optimization of Surface roughness and Machining Induced Vibratio...theijes
This paper presents the machining induced vibration and surface roughness modeled, predicted and optimized as functions of the cutting tool overhang, feed rate and cutting speed during hard and high speed turning of 41Cr4 alloy structural steel on an engine lathe machine with a carbide tool. The response surface methodology, based on central composite design of experiment was adopted, and analysis facilitated by using the Design Expert 9 software to generate and validate the models, predict the effect of the process variables on the response variables as well as obtain the optimum setting of the process variables that would minimize the response variables. Quadratic regression models were suggested as best fit for the measured machining induced vibration and surface roughness data. All the model terms of the machining induced vibration are significant with exception of the square term of the tool overhang. Whereas, all those of the surface roughness are significant with exception of the linear term of the tool overhang. The optimum setting of the cutting tool overhang at 57.8784 mm, feed rate at 0.15 mm/rev and the cutting speed at 328.507 rev/min minimized the machining induced vibration to a value of 0.18 mm/s2 , and the surface roughness to a value of 4.399 µmm with desirability of 0.822. Within the selected experimental design limits, the obtained response surface models can be used to accurately predict and optimize the machining induced vibration and surface roughness as functions of the tool overhang, feed rate and cutting speed during hard turning of 41Cr4 alloy structural steel.
Optimization of Force and Surface Roughness for Carbonized Steel in Turning P...IJERA Editor
These days one of the most important machining processes in industries is turning. Turning is affected by many
factors such as the cutting velocity, feed rate, depth of cut and geometry of cutting tool etc., which are input
parameters in this paper work. The desired product of dimensional accuracy and less surface roughness is
influenced by cutting force and tool vibration which are the responses and the functions of these input
parameters. In this paper work we determine the optimal setting of cutting parameters cutting speed, depth of
cut, feed and of the tool by using artificial neural network to get a maximum cutting force an minimum surface
roughness. This study highlights the use of modern optimization technique to optimize the multi response in
turning operation.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Experimental study of Effect of Cutting Parameters on Cutting Force in Turnin...AM Publications
Abstract: The purpose of this paper is to study the effect of cutting parameters on cutting force (Fc) & feed force in turning
Process. Experiments were conducted on a precision centre lathe and the influence of cutting parameters was studied using
analysis of variance (ANOVA) based on adjusted approach. Based on the main effects plots obtained through full factorial
design, optimum level for surface roughness and cutting force were chosen depth of cut, and the interaction of feed and depth of
cut significantly influenced the variance. In case of surface roughness, from the three levels of cutting parameters considered
Linear regression equation of cutting force has revealed that feed, the influencing factors were found to be feed and the
interaction of speed and feed. As turning of mild steel using HSS is one among the major machining operations in
manufacturing industry, the revelation made in this research would significantly contribute to the cutting parameters
optimization
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
The term steel is used for many different alloys of iron. All steels cover small amounts of carbon and manganese. There do exist many types of steels which are(among others) plain carbon steel, stainless steel, alloysteel and tool steel. Carbon steel is the most extensively used kind of steel. The properties of carbon steel depend mainly on the amount of carbon it contains. Maximum carbon steel has a carbon content of less than 1%. Carbon steel is made into an extensive range of products, including structural beams, car bodies. In fact, there are 3 types of plain carbon steel namely low carbon steel, medium carbon steel, high carbon steel. It is good to exact that plain carbon steel is a type of steel having a maximum carbon content of 1.5% along with small percentages of silica, Sulphur, phosphorus and manganese. EN 1010 is a lowest amount of carbonalloy steel alloy with carbon content of 0.10%. Machineability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is usually used for rivets and bolts, construction and automotive applications such as pans, nails and transmission cover. The objective of paper is to study the effect of process parameters namely pulse on time, pulse off time, peak current and servo voltage on surface roughness(SR).The effect of process parameters on productivity and accuracy facts is material dependent. To study parametric effect on Surface Roughness a Central Composite design approach of response surface methodology (RSM) is used to plan and study the experiments. The mathematical relationships between WEDM input process parameters and response parameter namely surface roughness is established to determine optimal values of surface roughness mathematically and graphically.The Analysis of variance (ANOVA) is performed to find statistically significant process parameters. Interaction effects of process parameters on surface roughness are analysed using statistical and graphical representations.
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Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year.
1. RESEARCH INVENTY: International Journal of Engineering and Science
ISBN: 2319-6483, ISSN: 2278-4721, Vol. 1, Issue 8 (November 2012), PP 01-06
www.researchinventy.com
Identification of stability lobes in high-speed machining of thin
ribs
1
Mr.P.Pal Pandian, 2Dr.V.Prabhu Raja, 3Mr. K.Sakthimurugan
1
Research Scholar, Department of Mechanical Engineering, Anna University,
Chennai – 600 025, India.
2
Associate Professor, Department of Mechanical Engineering, PSG College of Technology,
Coimbatore – 641 004, India.
3
Lecturer, Department of Mechanical Engineering, M.P. Nachimuthu M. Jaganathan Engineering College,
Erode – 638 112, India
Abstract - High speed machining of low rigidity structures is a widely used process in the Aeronautical
industry. Along the machining of this type of structures, the so-called monolithic components, large quantities of
material are removed using high removal rate conditions, with the risk of the instability of the process. Very thin
walls will also be milled, with the possibility of lateral vibration of them in some cutting conditions and at some
stages of machining. Chatter is an undesirable phenomenon in all machining processes, causing a reduction in
productivity, low quality of the finished work pieces, and a reduction of the machine-spindle’s working life. In
this study, a method for obtaining the instability or stability lobes, considering dynamic behaviors of machine
structure is presented. Thus a stability lobe diagram (SLD) has been developed analytically for machining of
thin ribs. The frequency response function (FRF) of the milling process has been predicted along with real and
imaginary parts. The mathematical tool MathCAD 8 Professional is used to simulate the FRF and stability
lobes. The experiment setup is proposed to find the impulse response of the machine structure at tool tip. Finally
the stable and unstable region for high speed machining process has been predicted analytically.
Keywords – Chatter, High speed machining, Machining vibrations, Stability lobe diagrams, Thin ribs
I. INTRODUCTION
The manufacturing process of monolithic components is widely used in the aeronautical sector for the
manufacturing of airframe components. The great number of these work pieces is manufactured by high speed
milling, where problems can arise related to the breakage of the tools, instability in the process and dimensional
errors in the work pieces. The instability of the process is a vibration phenomenon known as chatter, which
causes the abovementioned effects. Chatter phenomena appear in the high removal rate roughing, as well as in
the finishing of low rigidity airframe components.The stability of machine tool is dependent on the dynamic
behavior of machine tool structure, which is often expressed in terms of the frequency response function (FRF)
of the system at the tool point[1].Tang et al [2] describes the development of this new method which allows
considering the effects of multi-mode dynamics of system, higher excited frequency (i.e. tooth passing
frequency) and wider spindle speed range on stability limits in high-speed milling, and these to help in selection
of milling parameters for a maximum material removal rates (MRR) in real operations without chatter. Lopez et
al [3] describes a technique to vary spindle speed in order to obtain a stable cut. Use of this technique requires a
diagnosis and detection of the emergence of chatter vibrations.
Heisel and Feinauer [4] considered the dynamic influence of work piece quality in high speed milling.
They also considered the tool, tool holder and spindle dynamics to predict the effect of vibration on surface
quality. Zhongqun and Qiang [5] presents a predictive time-domain chatter model for the simulation and
analysis of the dynamic milling process and makes synthetic use of several chatter stability criteria to overcome
the limitation imposed by the single chatter stability criterion. In order to take into account the dynamic
regenerative effects, the instantaneous undeformed chip thickness is modeled to include the dynamic
modulations caused by the tool vibrations.Stepan et al [6] introduced two analytical methods for stability
prediction of general milling operations. The finite element analysis in time (FEAT) method and the semi-
discretization (SD) method. Both methods form a finite dimensional transition matrix as an approximation of the
infinite dimensional monodromy operator.Altintas et al [7] presented frequency and discrete time domain
chatter stability laws for milling operations in a unified manner. The time periodic dynamics of the milling
process are modeled. By averaging time varying directional factors at cutter pitch intervals, the stability lobes
are solved directly and analytically. When the process is highly intermittent, which occurs at high speeds and
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2. Identification Of Stability Lobes In High-Speed…
low radial depth of cuts, the stability lobes are more accurately solved either by taking higher harmonics of
directional factors in frequency domain, or by using semi-discretization method. He compared the stability
solutions against the numerical solutions and experiments, and provides comprehensive mathematical details of
both fundamental stability solutions.
Fig. 1. Example of a stability diagram.
Peres et al [8] described the development of new method which obtains the stability information for some
vibration modes that can be used to graph the stability lobes for high-speed milling, and these to help in the
selection of parameters for chatter free operations.Tobias [9] assumed that the direction of the cutting force as
well as the projected vibrations along the chip thickness are constant, which is true for single point cutting
operations like turning, boring and broaching. He also included the influence of the phase between the inner and
outer waves left on the chip surface, and invented stability lobes. Fig.1 shows the sample unstable and stable
regions of stability is given with the stability lines.
In paper presents an analytical method to predict the stability lobes for high speed machining process. The real
and imaginary parts of frequency response function are simulated using MathCAD software. The experimental
setup is proposed in order to measure the impulse response of the machine structure at the tool tip.
II. A METHOD TO IDENTIFY THE STABILITY LOBES
2.1 THE CHATTER Problem
In the milling process, material is removed from a workpiece by a rotating cutting tool. While the tool
rotates, it translates in the feed direction at a certain speed. A schematic representation of the milling process is
shown in Fig. 2.
Fig. 2. Mechanical model for milling.
One of the most common problems in machining is dynamic deformations, which are structural vibrations
between the cutting tool and the workpiece. The most common vibrations are the self-excited vibrations of
chatter, which grow until the tool leaves its cutting zone due to the exponential increase of the dynamic
displacements between the tool and the workpiece (regenerative chatter).Chatter occurs in machining operations
due to the interaction between the tool-workpiece structure and the force process. Regenerative chatter is so
named because of the closed-loop nature of this interaction (Fig. 3). Each tooth pass leaves a modulated surface
on the workpiece due to the vibrations of the tool and workpiece structures, causing a variation in the expected
chip thickness.Under certain cutting conditions (i.e. feed of rate, depth of cut, and spindle speed), large chip
thickness variations and hence force and displacement variations occur and chatter is present. The results of
chatter include a poor surface finish due to the chatter marks, excessive tool wear, reduce dimensional accuracy,
and tool damage. Machine-tool operators often select conservative cutting conditions to avoid chatter, thus,
decreasing productivity.
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3. Identification Of Stability Lobes In High-Speed…
2.2 Governing Equations Of Machine Chattering
The method to generate the stability lobes for a certain vibration mode identifies the transfer function
of the system with the experimental analysis. The natural frequency (ω), damping factor (ζ) and stiffness of the
mechanical system (k) are determined analytically. Once these values are found, the real (AR) and the
imaginary (AI) components of the transfer function for a certain chatter frequency can be calculated using:
1 r2
AR [1]
k[(1 r 2 ) 2 (2 .r ) 2 ]
2 .r
AI [2]
k[(1 r 2 ) 2 (2 .r ) 2 ]
C
where r and C is a chatter frequency.
It is necessary also to consider the average number of teeth during the cut (m):
N PR
m [3]
2 H
where H is the tool diameter, N the number of teeth of the tool and PR the radial depth of cut.
Fig. 3. Closed-loop representation of machining.
The axial depth of cut limit of stability is calculated with the following equation:
1
alim [4]
2 K m .m. AR
where μ is directional orientation factor and Km the cutting stiffness. The spindle speed n is simply calculated by
finding the tooth passing period:
1 60
T ( 2k ) n [5]
C NT
where N is the number of the tool teeth. To identify the phase shift (ε) between the inner and outer modulations
(present and previous vibrations marks), with the equation:
AR
2 (2 cot( )) [6]
AI
The new proposed method to identify the stability lobes for high-speed milling using a combination between the
analytical prediction of chatter and the experimental modal analysis for multi degree-of freedom systems is:
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4. Identification Of Stability Lobes In High-Speed…
Step 1: Obtain the characteristics of the tool, material to mechanise and milling process, and obtain the
characteristics of the system using the experimental analysis of the system;
Step 2: Calculate the real and imaginary component of the transfer functions (AR, AI), Eq. (1&2);
Step 3: Select a chatter frequency from the transfer function around a dominant mode;
Step 4: Calculate the critical depth of cut from Eq. (4);
Step 5: Calculate the spindle speed from n=60/NT for each stability lobe k = 0, 1, 2, and,
Step 6: Repeat from step 2 by scanning the chatter frequencies.
To obtain the stability lobes of all the vibration modes, it is necessary apply this method to all dominant modes
of the structure evident on the transfer functions. It is the superposition of all the stability lobes the one that
indicates the stable and unstable zone for milling.
III. PROPOSED EXPERIMENTAL SETUP TO FIND IMPULSE RESPONSE
Transfer functions of existing multi degree-of-freedom systems are identified by a structural dynamic
test. An impact hammer instrumented with a piezoelectric transducer and a accelerometer can be used as shown
in Fig. 4. With this method, we try to excite a range of frequencies that contain the natural modes of the
system. In order to obtain our objective, we need to generate an impulse and this can be given with a short
impact. To choose the appropriate hammer and sensor, we have to consider the mass, the stiffness and the
material of the structure.
Fig. 4. Schematic representation Impact hammer test
The real and imaginary parts of the FRF can be taken by interfacing with LabVIEW. The FRF from the
simulation and experiment can be compared to find the agreement of values.
IV. ANALYTICAL SIMULATION OF FRF USING MATHCAD SOFTWARE
The simulation is carried out by selecting following input parameters., helix angle of the tool 30 0,
natural frequency of the system 160 rad/sec, operating speed range 0-40,000 rpm, damping factor 0.02, stiffness
of the work piece 100 N/mm, operating stiffness 5.9 x 10 3 N/mm, tool diameter 19mm, no of teeth 2 and radial
depth of cut 0.1mm.The simulation of real part of the FRF from Eq. (1) shows the phase shift from positive
region to negative region as shown in Fig. 5.
Fig. 5. Simulational part of FRF
Fig. 6. Simulation of imaginary part of FRF
The simulation of imaginary part of FRF shows that the curve lies only in the negative region. The lobes can be
generated by negative region of the real part.
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5. Identification Of Stability Lobes In High-Speed…
Fig. 7. Minimum of Real part of FRF (f n=fc)
Fig. 8. Prediction of Lobe 0 from the real part of FRF
The lobe 0 can be drawn by inferring the minimum values of real part of FRF as shown in Fig. 7 and
substituting in Eq (4 & 5) gives the axial depth of cut limit and speed in rpm as shown in Fig. 8.The successive
lobes can be generated by using Eq (5) substituting k=0,1,2….; that resembles the Fig. 9.
Fig. 9. Depiction of multiple stability lobes
The stability lobes considering the selected input parameters are drawn as Excel chart showing Lobe 0, Lobe 1,
Lobe 2 and Lobe 3 as shown in Fig. 10. Since the series of relationship curves in Fig. 10 are shaped like lobes,
the graph is usually called a stability lobe diagram. A stability lobe diagram shows the relationship between chip
width (or depth of cut) and spindle speed, with the lobe number as a parameter.
Stability Lobe Diagram
7
6
Axial Depth of cut (mm)
5
4 Lobe0
Lobe1
Lobe2
3 Lobe3
2
1
0
0 5000 10000 15000 20000 25000 30000 35000 40000
Spindle Speed (rpm)
Fig. 10.Analytical Stability lobe diagram
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6. Identification Of Stability Lobes In High-Speed…
V. PROPERTIES OF THE STABILITY LOBE DIAGRAM
In a stability lobe diagram, a series of scallop-shaped lobes intersect with each other. These lobes form
the limits for chattering. Locally, for each lobe, it is stable below the lobe, and unstable above the lobe. Since
the lobes intersect, a point located below one lobe could be above the neighboring lobe. This point must be
treated as unstable. Therefore, globally, we must consider the relationship between adjacent lobes in
determining stability.ALL THE POINTS ABOVE THE CHATTER LINES ARE UNSTABLE, AND BELOW ARE STABLE. AS
SPINDLE SPEED INCREASES, THE LOBES BECOME WIDER WITH LARGER INTERVENING SPACES BETWEEN
CONSECUTIVE LOBES, AND INTERSECTION POINTS ARE HIGHER. THIS PHENOMENON CREATES A DESIRABLE
SITUATION FOR MACHINING AT BOTH HIGHER SPEED AND DEEPER CUT SIMULTANEOUSLY, AS WELL AS AT A WIDER
SPEED RANGE.
VI. CONCLUSION
In this paper, a new analytical method to obtain the information related to the stability of a machine-
tool-work piece system for a milling process was proposed. The simulation of FRF is based on the equations of
single degree of freedom system forced vibration. Considering the flexibility of the work piece will influence
more on stability lobes. The real and imaginary parts of FRF have been simulated using MathCAD software.
The experimental setup has been proposed for finding the impulse response of the machine structure at tool tip.
In future the experimental values will be adopted for predicting the stability lobes.
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