An Improved Method of Minimizing Tool Vibration during Boring Holes in Large-Size Structures

Abstract

The paper presents a thoroughly modified method of solving the problem of vibration suppression when boring large-diameter holes in large-size workpieces. A new approach of adjusting the rotational speed of a boring tool is proposed which concerns the selection of the spindle speed in accordance with the results of the simulation of the cutting process. This streamlined method focuses on phenomenological aspects and involves the identification of a Finite Element Model (FEM) of a rotating boring tool only and validating it with a real object, while dispensing with discrete modelling of a completely rigid workpiece. In addition, vibrations in the boring process in all directions were observed, which implies a geometric nonlinearity of the process model. During the simulation, the values of the Root Mean Square (RMS) of the time plots and the dominant values of the “peaks” in the displacement amplitude spectra were obtained. The effectiveness of the method was demonstrated using a selected mechatronic design technique called Experiment-Aided Virtual Prototyping (E-AVP). It was successfully verified by measuring the roughness of the indicated zone of the workpiece surface. The economic profitability of implementing the method in the production practice of enterprises dealing with mechanical processing is also demonstrated.

Equivalent linearization of hyperelastic rubber rings in dynamic vibration absorber boring bar and simulation of its dynamic properties

“…Houck III et al [19] achieved a new dynamic system by matching the natural frequency of the retainer with the natural frequency of the free-clamped boring bar. Kali'ski et al [20] proposed a new method for adjusting the rotational speed of the boring tool for the vibration suppression of large diameter holes for large workpieces. Nityananda et al [21] used an iterative inverse eigen sensitivity updating method to revise the finite element model of a boring bar.…”

The Selection of Cutting Speed to Prevent Deterioration of the Surface in Internal Turning of C45 Steel by Small-Diameter Boring Bars

“…In this context, small-diameter boring bars, despite their inherent low stability, are frequently utilized in certain applications where their use cannot be readily replaced. Consequently, researchers have directed their efforts towards improving machining parameters to enhance the process stability and optimize the turning performance when employing these small-diameter boring bars [6][7][8]. The use of small-diameter boring bars presents a complex challenge, as their reduced tool diameters necessarily result in lower rigidity and increased susceptibility to vibrations during machining.…”