Vibration of workpieces during aggressive turning operations

Abstract

Abstract. Turning is a widely used metal cutting operation. Because of the dynamic interaction between the cutter and the workpiece, vibration is excited during turning operations. If the vibration is severe, there will be degradation of surface quality of the workpiece, excessive wear and breakage of the cutter. Chatter can also take place. This paper presents a dynamic model for aggressive turning operations and considers the influence on vibration of the time-dependent reduction of workpiece diameter. The workpiece is modelled as a beam rotating about its longitudinal axis and the cutter provides a moving load. Simulated numerical examples are presented. IntroductionThe dynamic model of a rotating beam subjected to different loads has long been studied. Nevertheless, vibration remains a major problem in turning. Lee et al [1] and Katz et al [2] studied vibration of a rotating shaft as a beam based on Euler, Rayleigh, and Timoshenko beam theories under a transverse load moving at constant speed. Huang and his co-workers [3][4] investigated the response of the rotating cylindrical shell and spinning orthotropic beams subjected to harmonic moving loads. Argento and Scott [5] examined a rotating Timoshenko beam excited by a distributed surface force traveling with acceleration. Vibration of a rotating Timoshenko with general boundary conditions subjected to a moving load was investigated by Zu and Han [6]. Sinha [7] studied parametric stability of a rotor-disk system under a nonmoving dynamic axial load. Lee [8] introduced the axial force that was constant and nonmoving and found it had a significant effect on the magnitude of the dynamic response. Zibdeh and Juma [9] considered the moving load as a random force. El-Saeidy [10] analyzed boundary conditions of nonlinear stiffness due to clearance in rolling. He included bending moments in moving load and used the finite element method to study the rotating members subjected to moving load. Sheu and Yang [11] researched the dynamic response of a spinning Rayleigh beam with mass eccentricity but without moving load. Dassanayake and Suh [12] investigated a 3D model as a system of three rotors to simulate workpiece-tool deflections in response to a nonlinear regenerative force with a method of rotor dynamics. He studied different stages of stability for the workpiece and the tool. Ouyang and Wang [13] recently developed a dynamic model for the vibration of a rotating Rayleigh beam subjected to a three-directional load moving in the axial direction. They found that the

Modeling and Optimization of Hard Turning Operation on 41Cr4 Alloy Steel Using Response Surface Methodology

“…However, results obtained from surface roughness data are in close semblance. Besides, the study is supported by the work of Kassab and Khoshnaw [38], Han et al [39], Cahuc et al [40], Delijaicov et al [41], Rogov and siamak [42], [43], which considered essentially the machining induced vibration of either the cutting tool or work-piece as the response variable.…”

“…It occurs at the cutting zone due to interaction of the cutting tool, chips, and the work-piece. It is referred to as chatter [38], [39], [40], especially, when it is excessive. As chatter it can produce (a) a defective machined surface, and (b) an excessive wear and breakage of the cutting tool.…”

An Investigation on Effect of Depth of Cut, Feed Rate and Tool Nose Radius on Induced Vibration and Surface Roughness during Hard Turning of 41Cr4 Alloy Steel Using Response Surface Methodology

“…During machining, vibrations may occur due to sudden clash of a tool against a work-piece, irregular tissues of the work-piece, regular excitation due to asymmetric torque, and due to bearing defects. A sudden clash of a tool against a work-piece occurs at the cutting zone, and has been referred to as self-excited vibration, or if excessive, as chatter [38], [39], [40]. Chatter may give rise defective machined surface, and excessive wear and breakage of the cutting tool.…”

“…Also, a variety of work-piece materials, cutting tools, lathe machines, and parameter measurement instruments were used; and a variety of process variables and constants, and performance variables were investigated; with results obtained from surface roughness data in close semblance. The works of Kassab and Khoshnaw [38], Han et al [39], Cahuc et al [40], Delijaicov et al [41], Rogov and siamak [42], [43] are equally relevant, but essential to the machining induced vibration of either the cutting tool or work-piece. The same RSM, based on the central composite (CC) design of experiment, is used in this work to model, predict and optimize the machining induced vibration and surface roughness as functions of the tool nose radius, feed rate, and the depth of cut during hard turning of 41Cr4 alloy special steel, with a carbide cutting tool of the type F30, on a conventional lathe machine, using a surface roughness tester of the type ISR-16 and a vibration meter with transducer of the type 908 BE for the measurement of the surface roughness and machining induced vibration, respectively.…”

An Investigation on Effect of Depth of Cut, Feed Rate and Tool Nose Radius on Induced Vibration and Surface Roughness during Hard Turning of 41Cr4 Alloy Steel Using Response Surface Methodology

“…Submitted: 2016-03-01 ISSN: 2297-623X, Vol. 7, pp [32][33][34][35][36][37][38][39][40][41][42][43][44][45][46] Revised: 2016-03-25 doi:10.56431/p-08ad20…”