Abstract: Chatter vibrations, occurring during cutting process,
cause vibration between the cutting tool and workpiece, which
deteriorates surface roughness and reduces tool life. The purpose of
this study is to investigate the influence of cutting parameters and
tool construction on surface roughness and vibration in turning of
aluminum alloy AA2024. A new design of cutting tool is proposed,
which is filled up with epoxy granite in order to improve damping
capacity of the tool. Experiments were performed at the lathe using
carbide cutting insert coated with TiC and two different cutting tools
made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to
design of experiment and to optimize cutting conditions. By the help
of signal-to-noise ratio and analysis of variance the optimal cutting
condition and the effect of the cutting parameters on surface
roughness and vibration were determined. Effectiveness of Taguchi
method was verified by confirmation test. It was revealed that new
cutting tool with epoxy granite has reduced vibration and surface
roughness due to high damping properties of epoxy granite in
toolholder.
Abstract: Chatter vibrations and process instabilities are the
most important factors limiting the productivity of the milling
process. Chatter can leads to damage of the tool, the part or the
machine tool. Therefore, the estimation and prediction of the process
stability is very important. The process stability depends on the
spindle speed, the depth of cut and the width of cut. In milling, the
process conditions are defined in the NC-program. While the spindle
speed is directly coded in the NC-program, the depth and width of cut
are unknown. This paper presents a new simulation based approach
for the prediction of the depth and width of cut of a milling process.
The prediction is based on a material removal simulation with an
analytically represented tool shape and a multi-dexel approach for the
workpiece. The new calculation method allows the direct estimation
of the depth and width of cut, which are the influencing parameters of
the process stability, instead of the removed volume as existing
approaches do. The knowledge can be used to predict the stability of
new, unknown parts. Moreover with an additional vibration sensor,
the stability lobe diagram of a milling process can be estimated and
improved based on the estimated depth and width of cut.
Abstract: This paper investigates the occurrence of regenerative
chatter vibrations in facing and turning processes. Orthogonal turning
(facing) and normal turning experiments are carried out under stable
as well as in the presence of controlled chatter vibrations. The effects
of chatter vibrations on various sensor signals are captured and
analyzed using frequency domain methods, which successfully
detected the chatter vibrations close to the dominant mode of the
machine tool system.