Improving the Performance of Steel Machining Processes through Cutting by Vibration Control

Abstract

Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the improved construction version. In the first stage of the research, an analysis was made of the vibrations that appear in the cutting process when using the two types of tools. Vibration analysis considered the following: use of the Fast Fourier Transform (FFT) method, application of the Short-Time Fourier-Transformation (STFT) method, and observation of the acceleration of vibrations recorded during processing. After the vibration analysis, the roughness of the surfaces was measured and the parameter Ra was taken into account, but a series of diagrams were also drawn regarding the curved profiles, filtered profiles, and Abbott–Firestone curve. The research showed that use of the tool that is the improved constructive variant allows accentuated reduction of vibrations correlated with an improvement of the quality of the processed surfaces.

Process Stability Analysis during Trochoidal Milling of AZ91D Magnesium Alloy Using Different Toolholder Types

“…The result can be the inability to obtain the required properties of the manufactured part (dimensional accuracy or surface quality) [1]. The described problem may occur during rough machining [2][3][4], while it may be particularly relevant during finishing [5] and precision and ultraprecision machining, especially for low-rigidity parts. There can be multiple causes of instability during machining.…”

Modeling and Machine Learning of Vibration Amplitude and Surface Roughness after Waterjet Cutting

“…One of the disadvantages of the abrasive waterjet (AWJ) cutting process is its inherent instability, leading to vibrations that negatively impact the quality of the cutting edge and surface [18,19]. However, monitoring these vibrations during the cutting process presents an opportunity to enhance the stability and reliability of the process, consequently influencing the quality of the surface and edges after cutting [20,21].…”