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Effect of Speed, Feed and Depth of Cut on Vibration of Cutting Tool

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Effect of Speed, Feed and Depth of Cut on Vibration of Cutting Tool 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 machining. 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 turning 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 milling, 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 machine tool 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 lathe. The selection of process parameters were determined by using Taguchi‘s experimental
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