Effect of Composite Material on Damping Capacity Improvement of Cutting Tool in Machining Operation Using Taguchi Approach

Authors: S. Ghorbani, N. I. Polushin

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.

Keywords: ANOVA, damping capacity, surface roughness, Taguchi method, vibration.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1110133

References:

[1] J. Serge, “Metal cutting mechanics and material behavior,” Technische universitiet Eindhoven, 1999.
[2] C. Thomas, M. Katsuhiro, O. Toshiyuki and Y. Yasuo, “Metal machining: Theory and applications,” Great Britain. Arnold, a member of the Hodder Headline Group, 2000.
[3] H. S. Qi and Bi. Mills, “Formation of a transfer layer at the tool-chip interface during machining,” International Journal of Wear, 2000, vol. 245, pp. 136–147.
[4] A. A. Tareq, “Extending the technological capability of turning operation,” International Journal of Engineering Science and Technology, 2009, vol. 2, no. 1, pp. 192–201.
[5] V. M. Luciano, C. J. Juan, R. C. Eduardo, H. R. Gilberto and L. G. Alejandro, “Analysis of compliance between the cutting tool and the workpiece on the stability of a turning process,” International Journal of Machine Tools & Manufacture, 2008, vol. 48, pp. 1054–1062.
[6] S. S. Kanase and V. S. Jadhav, “Enhancement of surface finish of boring operation using passive damper,” Indian Journal of Applied Research, 2012, vol. 2, no. 3, pp. 68–70.
[7] K. Ramesh and T. Alwarsamy, “Investigation of Modal analysis in the stability of boring tool using double impact dampers model development,” European Journal of Scientific Research, 2012, vol. 80, no. 2, pp. 182–190.
[8] D. Lorenzo, A. Andreas, and M. N. Cornel, “Design, implementation and analysis of composite material dampers for turning operation,” World Academy of Science, Engineering and Technology, 2009, vol. 3, no. 5, pp.556–563.
[9] P. F. Antonio and L. N. Flamínio, “Behavior of granite-epoxy composite beams subjected to mechanical vibrations,” ANNALS of Faculty Materials Research, 2010, vol. 13, no. 4, pp. 497–503.
[10] A. Selvakumar and P. V. Mohanram, “Analysis of alternative composite material for high speed precision machine tool structures,” ANNALS of Faculty Engineering Honedoara, Internationa Journal of Engineering, 2012, vol. 10, no. 2, pp. 95–98.
[11] F. Qilin, S. L. Gabriela, M. M. Rashid, S. Tuula, U. Juha, T. Geza, K. Krisztian, Ö. Tomas, M. N. Cornel, “Suppressing tool chatter with novel multi-layered nanostructuresof carbon based composite coatings,” Journal of Materials Processing Technology, 2015, vol. 223, pp. 292– 298.
[12] W. Min, Z. Tao, Y. Yiqing, F. Renyuan, “Design and implementation of nonlinear TMD for chatter suppression: An application in turning processes,” International Journal of Machine Tools & Manufacture, 2010, vol. 50, pp. 474–479.
[13] L. Mohit, A. Yusuf, P. A.Srikantha, “Rapid evaluation and optimization of machine tools with position-dependent stability,” International Journal of Machine Tools & Manufacture, 2013, vol. 68, pp. 81–90.
[14] S. S. Abuthakeer, P. V. Mohanram and K. G. Mohan, “Prediction and control of cutting tool vibration Cnc lathe with Anova and Ann,” Inter Journal of Lean Thinking, 2011, vol. 2, no. 1, pp. 1–23.
[15] L. N. Devin and A. A. Osaghchii, “Improving performance of cBN cutting tools by increasing their damping properties,” Journal of Superhard Materials, 2012, vol. 34, no. 5, pp. 326–335.
[16] K .K. Rama and J. Srinivas, “Study of tool dynamics with a discrete model of workpiece in orthogonal turning,” International Journal of Machining and Machinability of Materials, 2011, vol. 10, no. 1-2, pp. 71–85.
[17] M. Sortino, G. Totis and F. Prosperi, “Development of a practical model for selection of stable tooling system configurations in internal turning” International Journal of Machine Tools & Manufacture, 2012, vol. 61, pp. 58–70.
[18] M. Nouari, G. Lis, F. Girot and D. Coupard. “Experimental analysis and optimization of tool wear in dry machining of aluminum alloys,” Wear 2003, vol. 255, pp. 1359–1368.
[19] U. D. Gulhane, S. P Ayare, V. S. Chandorkare and M. M. Jadhav, “Investigation of turning process to improve productivity (MMR) for better surface finish of AL-7075-T6 using DOE,” International journal of design and manufacturing technology, 2013, vol. 4, no. 1, pp. 59–67.
[20] R. P. Pragnesh and V. A. Patel, “Effect of machining parameters on surface roughness and power consumption for 6063 Al alloy TiC composites (MMCs),” International Journal of Engineering Research and Applications, 2013; vol. 2, no. 4, pp. 295–300.
[21] N. B. Doddapattar and S. N.Lakhmana, “An optimization of machinability of alluminium alloy 7075 and cutting tool parameters by using Taguchi technique,” International Journal of Mechanical Engineering and Technology, 2012, vol. 3, no. 2, pp. 480–493.
[22] B. D. Narayana and S. B. Chenata, “Optimization of cutting parameters for turning alluminium alloy using Taguchi method,” International Journal of Engineering Research and Technology, 2013, vol. 2, no. 7, pp. 1399–1407.
[23] R. Horváth and K. A. Drégelyi. “Analysis of Surface Roughness Parameters in Aluminum Fine Turning with Diamond Tool. Measurement,” Proceedings of the 9th International Conference, Smolenice, Slovakia, 2013, pp.275–278.
[24] S. Raviraj, R. Pai, V. Kamath and S. S. Rao, “Study on surface roughness minimization in turning of DRACs using surface roughness methodology and Taguchi under presser steam jet approached,” ARPN Journal of Engineering and Applied Sciences, 2008; vol. 3, no. 1, pp. 59–67.
[25] T. Genichi, C. Subir, W. Yuin, “Taguchi’s Quality Engineering,” Handbook. New Jersey: John Wiley & Sons Inc, 2005.
[26] P. J. Ross, “Taguchi Techniques for Quality Engineering,” McGraw-Hill International Book Company, OH, 1996.
[27] G. Mustafa and Y. Emre, “Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron,” Measurement, 2013, vol. 46, pp. 913–919.