Analytical and experimental stability analysis of AU4G1 thin-walled tubular workpieces in turning process

Abstract

The development of the manufacturing-based industries is principally due to the improvement of various machining operations. Experimental studies are important in researches, and their results are also considered useful by the manufacturing industries with their aim to increase quality and productivity. Turning is one of the principal machining processes, and it has been studied since the 20th century in order to prevent machining problems. Chatter or self-excited vibrations represent an important problem and generate the most negative effects on the machined workpiece. To study this cutting process problem, various models were developed to predict stable and unstable cutting conditions. Stability analysis using lobes diagrams became useful to classify stable and unstable conditions. The purpose of this study is to analyze a turning process stability using an analytical model, with three degrees of freedoms, supported and validated with experimental tests results during roughing operations conducted on AU4G1 thin-walled tubular workpieces. The effects of the tubular workpiece thickness, the feed rate and the tool rake angle on the machining process stability will be presented. In addition, the effect of an additional structural damping, mounted inside the tubular workpiece, on the machining process stability will be also studied. It is found that the machining stability process is affected by the tubular workpiece thickness, the feed rate and the tool rake angle. The additional structural damping increases the stability of the machining process and reduces considerably the workpiece vibrations amplitudes. The experimental results highlight that the dynamic behavior of turning process is governed by large radial deformations of the thin-walled workpieces. The influence of this behavior on the stability of the machining process is assumed to be preponderant.

Multi-response optimization of the actively driven rotary turning for energy efficiency, carbon emissions, and machining quality

“…Step 1: The turning trails are performed to obtain necessary data. [29][30][31] The Box-Behnken method (BBM) is employed to produce the experimental matrix with the parameter combination. 32,33 The BMM is an effective design of the experimental method, which combines a two-level factorial design.…”

Numerical and Experimental Investigation on Dynamic Behavior in Turning Process of Thin-walled Workpieces made of 42CrMo4 Steel Alloy

“…This deformation can justify the displacements of the reference point (RP-1) located on the axis of revolution of the part. Using the analytical stability lobes model, described in [16], figure 10 shows comparison of the vibratory state of the roughing and finishing conducted tests with the stability lobes. For a workpiece with 6 mm thick, corresponding to roughing tests R-1, R-2 and R-3 (Fig.…”

“…Recently, Sahraoui et al, [15,16] presented an analysis of a turning process stability using an analytical model supported and validated with experimental tests results of roughing and finishing operations conducted on AU4G1 thin-walled tubular workpieces with different thickness values. They showed the important effects of the dynamic behavior of the thin walled workpieces on the stability criteria, which cannot be ignored in machining process planning and cutting parameters selection.…”

Experimental study on cutting force in ultrasonic vibration-assisted turning of 304 austenitic stainless steel

“…Turning is the most basic, most common and most extensive technical method in the mechanical manufacturing industry, which occupies a very important position in production. 5–8 Extensive use of turning leads many scientific research institutions and production and processing departments to carry on in-depth study on it, meanwhile the development of UAT is also promoted. UAT is different from traditional turning process, which changes from continuous cutting mode of conventional turning (CT) to interrupted cutting and is a typical composite machining method combining ultrasonic vibration with CT. 9–12…”