Analysis of vibration signals to quantify displacement amplitude in the monitoring of vibration-assisted turning

Abstract

Vibration-assisted machining combines precision machining with small-amplitude tool vibration at high frequency to improve the fabrication process. It has been applied to a number of processes from turning to drilling to grinding. This work presents the validation of tool condition monitoring system based on vibration parameters. For this purpose, an experimental investigation is planned to acquire vibration signal data during the machining. This work primarily focuses on quantifying the presence of relative vibrations between the cutting tool and a workpiece during vibration-assisted turning process which helps in predicting tool life. For this purpose, an online acoustic optic emission-based vibration transducer, i.e. Laser Doppler Vibrometer, is used as a component of a novel approach. Cutting force and vibration signals were recorded and analyzed. Machine dynamic effects such as cutting force and tool wear are taken into account during the dry machining of Ti-6Al-4V alloys specimens. Identifying the correlation among tool wear, cutting forces and displacement due to vibration is a critical task in the present study. Real-time experimental findings are used to predict the evolution of displacement and tool wear in the experiment. Efficacy of a logical relationship among the process variables such as displacement, feed rate, spindle rotational speed, and depth of cut is critically examined. Results of the present study are used to establish a strategy for real-time efficient tool monitoring systems for vibration-assisted turning operation. The wear mechanisms of DNMA 432 coated carbide and uncoated carbide insert tools were examined at different combinations of feed rate, spindle speed, and depth of cut for turning of Ti-6Al-4V workpiece material.

Parametric optimization while turning Ti-6Al-4V alloy in Mist-MQCL (Green environment) using the DEAR method

“…This trend agrees with previous works published [4]. As feed increases, vibrations vary and contribute to the surface finish [31]. With increased speed, SR, MRR, and Vib showed an increasing trend in the limits of (0.05 to 0.2 mm/rev) feed rate.…”

“…As per 'ISO-10816' standards for rotatingworkpiece, the amplitude of vibration up to 20 mm has a negligible impact on Tw. Tw effects when vibration amplitude in the workpiece ranges from 20 microns to 60 microns, and vibration amplitude beyond 60 microns needs attention [31]. From the results tabulated in Table 2, one can observe that as vibration amplitude is high, so is the surface roughness.…”

Modeling and optimization of dead metal zone to reduce cutting forces in micro-milling of hardened AISI D2 steel

“…7a, the amplitude of cutter vibration increased when the spindle speed and feed per tooth are increased. Murthy et al [10] and Prasad [14] Fig. 7 a Interaction effect of process parameters on Y, b interaction effect of tool parameters on Y Fig.…”

“…It was found that surface roughness is greatly affected by feed rate and dimensional accuracy is affected by tool wear and tool vibrations. Prasad et al [14] investigated effect of relative vibration between the work piece and the tool on the surface roughness and tool wear in vibration-assisted turning of Ti-6Al-4 V. They used LDV for online data acquisition of tool vibration during the machining process. They concluded that the cutting speed has significant effect on tool vibration and tool wear, whereas the feed rate was found to be responsible for surface roughness.…”

Correlation analysis of noise sound pressure and vibration in aluminum alloy milling

“…In addition, many scholars have studied the correlation between cutting vibration and tool wear and analyzed the impact of vibration on tool wear. Prasad et al (2016Prasad et al ( , 2019 analyzed the correlation between vibration amplitude and tool wear in dry turning of AISI 4140 steel using uncoated carbide insert DNMA 432.…”