Experimental Study of the Dynamic Behavior of Thin-Walled Tubular Workpieces in Turning Cutting Process

Abstract

Nowadays, industrialists, especially those in the automobile and aeronautical transport fields, seek to lighten the weight of different product components by developing new materials lighter than those usually used or by replacing some massive parts with thin-walled hollow parts. This lightening operation is carried out in order to reduce the energy consumption of the manufactured products while guaranteeing optimal mechanical properties of the components and increasing quality and productivity. To achieve these objectives, some research centers have focused their work on the development and characterization of new light materials and some other centers have focused their work on the analysis and understanding of the encountered problems during the machining operation of thin-walled parts. Indeed, various studies have shown that the machining process of thin-walled parts differs from that of rigid parts. This difference comes from the dynamic behavior of the thin-walled parts which is different from that of the massive parts. Therefore, the purpose of this paper is to first highlight some of these problems through the measurement and analysis of the cutting forces and vibrations of tubular parts with different thicknesses in AU4G1T351 aluminum alloy during the turning process. The experimental results highlight that the dynamic behavior of turning process is governed by large radial deformations of the thin-walled workpieces and the influence of this behavior on the variations of the chip thickness and cutting forces is assumed to be preponderant. The second objective is to provide manufacturers with a practical solution to the encountered vibration problems by improving the structural damping of thin-walled parts by additional damping. It is found that the additional structural damping increases the stability of the cutting process and reduces considerably the vibrations amplitudes.

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

“…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.…”

Influence of the Compliance of a Technological System on the Machining Accuracy of Low-Stiffness Shafts in the Grinding Process

“…The errors in the longitudinal section of the workpiece that occur during machining are caused by the low and uneven stiffness of the technological system, the main elements of which are the workpiece, the centers in which it is mounted, and the cutting tool [ 27 , 28 , 29 , 30 ]. The compliance (flexibility) of such a system can be altered by changing the stiffness of the centers or increasing the stiffness of the part in the machining process, for example, as a result of applying the appropriately defined bending moments [ 31 , 32 , 33 , 34 ].…”

Technological Methods for Controlling the Elastic-Deformable State in Turning and Grinding Shafts of Low Stiffness

“…It is especially important for machining parts with low stiffness when it is necessary to ensure their appropriate stiffness to enable efficient machining [ 22 ]. The accuracy and quality of machining may be increased as a result of the development and application of appropriate (close to optimal) structures of the control systems [ 23 , 24 ].…”