International Journal of Innovative and Emerging Research in Engineering Volume 4, Issue 5, 2017 Available online at www.ijiere.com International Journal of Innovative and Emerging Research in Engineering e-ISSN: 2394 – 3343 p-ISSN: 2394 – 5494

EFFECT OF SPEED, FEED AND DEPTH OF CUT ON VIBRATION OF CUTTING TOOL

Motgi Rakesh S.1a, Misal Nitin D.2b 1a ME (Mech-Design), SVERI’S College of Engineering, Pandharpur, Solapur University, India. 2bAssociate Professor, SVERI’S College of Engineering, Pandharpur, Solapur University, India

ABSTRACT In the era of industrialization and production modern technology is very crucial. Extensive research work is being carried out from decades to find appropriate solutions in the field of . In earlier studies effect of speed, feed and depth of cut is undertaken but its effect along with vibration on surface roughness is needed to be studied. These papers demonstrate the usefulness of Finite Element Method for investing the effect of speed, feed and depth of cut on the vibration of cutting tool during operation. Finite Element analysis is done by using FEM to see the nature of vibrations. Further validation of FEM results is done by using Vibrometer for vibrations developed during machining. This paper focuses on relationship between four elements viz. speed, feed, depth of cut and vibration. Results obtained during dissertation are apparently closer. Keywords:Vibration, Cutting Parameters, turning, speed, feed, depth of cut, FEA

I. INTRODUCTION In a machining operation, vibration is frequent problem, which affects the machining performance and in particular, the surface finish and tool life. Severe vibration occurs in the machining environment due to a dynamic motion between the cutting tool and the work piece. In all the cutting operations like turning, boring and , vibrations are induced due to the deformation of the work piece, machine structure and cutting tool. In a machining operation, forced vibration and self-excited vibration are identified as machining vibrations.Forced vibration is a result of certain periodical forces that exist within the machine, bad gear such as drives, misalignment, and unbalanced components, etc. Self- excited vibration is caused by the interaction of the chip removal process and the structure of the machine tool, which results in disturbance in the cutting zone. The self-excited vibration affects the production capacity, reliability and machining surface quality [2].

II.LITERATURE REVIEW LI Haoshenget. al. [4] studied, signal processing techniques to relate workpiece surface topography to the dynamic behavior of the machine tool. Spatial domain frequency analyses based on fast Fourier transform were used to analyze the tool behavior. Wavelet reconstruction was used for profile filtering. The results show that machine vibration remarkably affects the surface topography at small feed rates, but has negligible effect at high feed rates. The analyses also show how to control the surface quality during hard turning. CM Tayloret. al. [5] studied Regenerative vibration, or chatter, limits the performance of machining processes. Consequences of chatter include tool wear and poor machined surface finish. Process damping by tool-workpiece contact can reduce chatter effects and improve productivity. An analytical model of cutting with chatter leads to a two-section curve describing how process damped vibration amplitude changes with surface speed for radiussed tools. A rule of thumb is proposed which could be useful to machine operators, regarding tool wear and process damping. Cornelius Scheffer[9]in his study concluded that the force signal, thrust force is more sensitive to the diamond tool wear than vibration signal. He also developed an automated diamond tool wear monitoring system that can be implemented on-line D.E. Dimlaet. al. [10]studied and found that vertical components (z-direction) of both cutting forces and the vibration signatures were the most sensitive to tool wear, with nose wear being the most useful indicator of eminent tool failure. The cutting conditions invariable are a major factor affecting the process parameters. Their independence in the design of any TCMS cannot therefore be neglected evident by variation in the sensitivity of the cutting forces (static and dynamic) as well as the vibration components to both tool wear and cutting conditions Muhammad Munawaret.al. [11] from their study found that poor control on the desired surface roughness generates non-conforming parts and results into increase in cost and loss of productivity due to rework or scrap. Surface roughness value is a result of several process variables among which machine tool condition is one of the significant variables. In 77

International Journal of Innovative and Emerging Research in Engineering Volume 4, Issue 5, 2017 the experimentation variable used to represent machine tool's condition was vibration amplitude. Input parameters used, besides vibration amplitude, were feed rate and insert nose radius. Study revealed that vibration amplitude and feed rate had moderate effect on the surface roughness and insert nose radius had the highest significant effect on the surface roughness. It was also found that a machine tool with low vibration amplitude produced better surface roughness. Insert with larger nose radius produced better surface roughness at low feed rate Safeen Y. Kassabet. al. [12] in their study concluded that cutting tool acceleration has asignificant effect on surface roughness of workpiece. The surface roughness of work piece is proportional to cutting tool acceleration. This effect interacts with other independent variables such as feed rate cutting speed and depth of cut. The acceleration of the cutting tool increases with the increasing of the cutting tool overhang for different cutting conditions. Thus the vibration of cutting tool depends strongly on cutting tool overhang. With the increasing feed rate the surface roughness of work piece will increase. The feed rate can be considered as a main cutting factor in the machining operation. Increasing cutting speed leads to a decrease in surface roughness of workpiece. Depth of cut has small effect on surface roughness of work piece in this study. Parallel to the tool vibration the surface roughness of work piece increases with increasing the cutting tool overhang. The effect of cutting tool vibration in feed direction could be neglect, if compared with that in vertical direction. PrajwalSripathi[1]in his study found that the cutting force and the thrust force increases significantly with increase in feed. The cutting force and thrust force decreases marginally with the increase in rake angle from -100 to 00 but decreases rapidly with the increase in rake angle from 00 to 300. Tool surface roughness increases with the increase in feed from 0.001 inch to 0.005 inch. M. Dogra, V. S. et. al. [2]studied the effect of cutting tool geometry issue in understanding mechanics of turning. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning. They presented a survey on variation in tool geometry i.e. tool nose radius, rake angle, groove on the rake face, variable edge geometry, wiper geometry and curvilinear edge tools and their effect on tool wear, surface roughness and surface integrity of the machined surface. TugrulOzel et al. [6]studied the effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated. Four-factor (hardness, edge geometry, feed rate and cutting speed) two-level fractional experiments were conducted and statistical analysis of variance was performed. During hard turning experiments, three components of tool forces and roughness of the machined surface were measured. They found that the effects of workpiece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant ZahariTaha[7]compared measured surface roughness from experiment with theoretical surface roughness of two different inserts, C and T type. Experiment focused on the turning process. Feed rate was varied and it observed that large deviation between measured and theoretical surface roughness at low feed rates for both inserts C.O. Izeluet. al. [8]studied the effect of turning parameters on induced vibration and work surface roughness of 41Cr4 alloy steel. Response Surface Methodology in conjunction with third order composite factorial Design is used to evaluate the effect of turning parameters on induced vibration amplitude and surface roughness. They observed that turning parameters (depth of cut, cutting speed and work piece overhang) had significant effect on the surface roughness of work piece, and to a relative degree, influenced induced vibration. It also shows that the induced vibration and surface roughness of workpiece is directly proportional to the depth of cut, cutting speed and work piece overhang Renjith V. B. et.al. [14]studieddeflection of cutting tools during machining and how it affects tool life, surface roughness and dimensional correctness. In their work, deflection of a T-42 CT H.S.S single point cutting tool is investigated by varying rake angle, cutting feed and tool extension length during turning operation on . The selection of process parameters were determined by using Taguchi‘s experimental design method. Cutting force components during turning operation were measured by lathe tool force dynamometer. The degree of influence of each process parameter on cutting force and deflection was studied and the optimal values that minimize deflection were determined. Finally an empirical relationship between deflection and input parameters is formulated.

III. EXPERIMENTAL PROCEDURE A. MATERIAL, TOOL AND EQUIPMENT USED. i.Material SS304 SS304 is nonmagnetic in nature. Type 304 is an austenitic grade that can be severely deep drawn. This property has resulted in 304 being the dominant grade used in applications like sinks and saucepans. Type 304L is the low carbon version of 304.

Table 1 Chemical Composition of SS304 C Mn Si P S Cr Ni N % 0.08Max 2 0.75 0.045 0.03 18-20 10.5 0.1

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International Journal of Innovative and Emerging Research in Engineering Volume 4, Issue 5, 2017 Table 2 Mechanical Properties of SS304 Tensile Compression Proof Stress Elongation A5 Hardness Property Strength Strength 0.2% (MPa) (%) Rockwell B (MPa) (MPa) Value 520 210 210 45 92

ii. Tool ISO 6L2525

Table 3. Specification of the Cutting Tool [13]

Dimensions Ordering Tip 2 Code h b l1 f1 f2 ap rɛ ᵧ1 λ ISO 6L2525 C10 12 12 140 35 15.5 20 1.2 120 00 1212 “Fig 1.Dimensions of ISO 6L 2525.” iii. Vibrometer The machine condition advisor Vibrometer provides an overall velocity vibration reading that measures vibration signals from the machine and automatically compares them to pre-programmed international organization for standardization. When performing measurement the machine condition advisor acceleration produces two different measurements for each point on the machinery- overall velocity and enveloped acceleration. Depending on SKF machine condition advisors system setting, the front –panel LCD simultaneously displays iv. CNC Machine

“Fig 2 SKF Machine Condition Advisor” “Fig 3 Ace Micromatic CNC Machine” v. Surface Finish Tester Here MitutoyoSurftest SJ-210 is used for measuring surface roughness of machined component

Fig 4MitutoyoSurftest SJ-210 79

International Journal of Innovative and Emerging Research in Engineering Volume 4, Issue 5, 2017 B. MACHINING A test piece of SS 304 material is clamped in three jaw of CNC machine and initial rough cutting is done. Then 10 mm cut is taken for each speed, feed and depth of cut for parameters values in table 4. Probe of machine condition advisor is made to touch to turning tool while turning operation and peak acceleration for each set of parameters is found. Results obtained during machining and by FEM are as indicated in table 4.

(a) (b) Fig 5Turning (a) Machining Operation (b) Machined Component

C. FINITE ELEMENT ANALYSIS OF MACHINING

GEOMETRY MESHING

LOADING POST PROCESSING RESULTS

Fig. 6 FEA IV. RESULT AND CONCLUSIONS

TABLE 5. COMPARISON BETWEEN FINITE ELEMENT AND EXPERIMENTAL RESULTS

Peak Peak Sr. Depth Feed Speed acceleration acceleration Deviation No. (mm) (mm/rev) (rpm) (m/s2) (m/s2) FEA in % experimental 1 0.5 0.1 140 0.0500 0.0480 4 2 0.5 0.1 220 0.0560 0.0540 3.57 3 0.5 0.1 360 0.0710 0.0680 4.22 80

International Journal of Innovative and Emerging Research in Engineering Volume 4, Issue 5, 2017 4 0.5 0.16 140 0.0580 0.0539 7.06 5 0.5 0.16 220 0.0620 0.0595 4.03 6 0.5 0.16 360 0.0670 0.0648 3.28 7 0.5 0.25 140 0.0710 0.0713 0.4 8 0.5 0.25 220 0.0790 0.0710 10.12 9 0.5 0.25 360 0.0800 0.0820 2.5 10 0.6 0.1 140 0.0860 0.0845 1.74 11 0.6 0.1 220 0.0920 0.0877 4.67 12 0.6 0.1 360 0.1140 0.1102 3.33 13 0.6 0.16 140 0.1070 0.1079 0.85 14 0.6 0.16 220 0.0830 0.0807 2.77 15 0.6 0.16 360 0.0980 0.0990 1.02 16 0.6 0.25 140 0.1170 0.1138 2.73 17 0.6 0.25 220 0.1080 0.104 3.70 18 0.6 0.25 360 0.1150 0.1090 5.21 19 0.7 0.1 140 0.1020 0.0990 2.94 20 0.7 0.1 220 0.0690 0.0678 1.73 21 0.7 0.1 360 0.0760 0.0736 3.15 22 0.7 0.16 140 0.0830 0.0820 1.2 23 0.7 0.16 220 0.0960 0.0930 3.125 24 0.7 0.16 360 0.1100 0.1050 4.45 25 0.7 0.25 140 0.0940 0.0910 3.2 26 0.7 0.25 220 0.1120 0.1145 2.23 27 0.7 0.25 360 0.1060 0.0977 7.83

In this work behavior of vibration of the cutting tool was observed by changing cutting parameters i.e; the speed, feed and the depth of cut. SS 304 was taken as the workpiece material; the cutting tool was ISO 6L 2525 and also the vibration is represented by the peak acceleration of the cutting tool. As there were 3 factors each having three levels so a total of 27 experiments were done by varying the factors and the data thus obtained is validated by using FEA method.It is observed that -Depth of cut is the most important factor in controlling the vibration of the cutting tool as it increases the longitudinal as well tangential cutting force leading surge in vibration. -Experiment as well FEA shows cutting speed plays negligible role in chatter effect.

REFERENCES [1] Prajwal Sripathi, “ Investigation into the Effects of Tool Geometry and Metal Working Fluids on Tool Forces and Tool Surfaces During Orthogonal Tube Turning of Aluminum 6061 Alloy” , Auburn University, 2009, pp. 1-2 [2] M. Dogra, V. S. Sharmab, J. Dureja, “Effect of tool geometry variation on finish turning – A Review”, Journal of Engineering Science and Technology Review, 2011, pp. 1-2 [3] S.S. Abuthakeer, P.V. Mohanram, G. Mohan Kumar, “Prediction and Control of Cutting Tool Vibration in CNC Lathe with Anova and Ann”, International Journal of Lean Thinking, Volume 2, Issue 1, 2011, pp. 2 [4] LI Haosheng, WU Su, Hubert Kratz, “FFT and Wavelet-Based Analysis of the Influence of Machine Vibrations on Hard Turned Surface Topographies”, Tsinghua Science and Technology ISSN 1007-0214, Volume 12, 2007, pp. 1 [5] CM Taylor, ND Sims and S Turner, “Process Damping and Cutting Tool Geometry in Machining”, Trends in Aerospace Manufacturing, International Conference, 2009, pp. 1 [6] TugrulOzel, Tsu-Kong Hsu, ErolZeren, “Effects of Cutting Edge Geometry, Workpiece Hardness, Feed Rate and Cutting Speed on Surface Roughness and Forces in Finish Turning of Hardened AISI H13 Steel”, International Journal on Advanced Manufacturing, 2005, pp. 1 [7] ZahariTaha, “Effect of Insert Geometry on Surface Roughness in the Turning Process of AISI D2”, 11th Asia Pacific Industrial Engineering and Management System Conference, 2010, pp. 2-3 [8] C.O. Izelu, S.C. Eze, B.U. Oreko, B.A Edward,“ Effect of Depth of Cut, Cutting Speed and Work-piece Overhang on Induced Vibration and Surface Roughness in the Turning of 41Cr4 Alloy Steel”, International Journal of Emerging Technology and Advanced Engineering, 2014,Volume 4, Issue 1, pp. 1 [9] Cornelius Scheffer, Monitoring of Tool Wear in Turning Operation Using Vibration Measurement, University of Pritoria, 1999, pp. 1 [10] D.E. Dimla, P.M. Lister, “On-line metal cutting tool condition monitoring. I: force and vibration analyses”, International Journal of Machine Tools & Manufacture, 2000, PP. 1 [11] Muhammad Munawar, Nadeem Mufti and Hassan Iqbal, “Optimization of Surface Finish in Turning Operation by Considering the Machine Tool Vibration using Taguchi Method”, Mehran University Research Journal of Engineering & Technology, Volume 31, 2012 pp. 51 81

International Journal of Innovative and Emerging Research in Engineering Volume 4, Issue 5, 2017 [12] Safeen Kassab and Younis Khoshnaw, “The Effect of Cutting Tool Vibration on Surface Roughness of Workpiece in Dry Turning Operation”, Eng. & Technology, Vol.25, 2007, pp. 879 [13] Brazed Turning Tools”, Sandvik Coromant Information Brochure. [14] Renjith V. B., Mathew Baby and K. R. Jayadevan, “ Influence of Process Parameters on Cutting Forces and Taguchi Based Prediction of T42 - CT H.S.S Single Point Cutting Tool Deflection”, International Journal of Scientific and Research Publications, Volume 3, Issue 7, 2013, pp. 1 [15] http://cadem.com/cncetc/cnc-turning-surface-finish-nose-radius/ [16] Materials and Manufacturing Processes, Lab Manual, 2010, pp.3 [17] http://www.finiteelement.com/feawhite4.html

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