Influence of magnetorheological elastomer on tool vibration and cutting performance during boring of hardened AISI4340 steel

Lawrance, G.; Paul, P. Sam; Vasanth, X. Ajay; Varadarajan, A.; Daniel, Esther

doi:10.1007/s12206-019-0307-0

Cited by 23 publications

(7 citation statements)

References 15 publications

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“…This is the first study that uses and MRE in a torsional mode for vibration absorption and thus broadens the application of the MRE. Similarly, another new application of MRE has been piloted by Lawrance et al [207], they used MRE to suppress tool vibration and improve cutting performance of the boring process, in machining, boring is the process of enlarging a hole that has already been drilled. The vibration, which occurs due to the interaction of the cutting process and machine tool, can be suppressed by adding the MRE to the tool holder.…”

Section: Vibration Absorbersmentioning

confidence: 99%

Recent progress of magnetorheological elastomers: a review

Bastola¹,

Paudel²,

Li³

et al. 2020

Smart Mater. Struct.

123

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Magnetorheological elastomers (MREs) are one of the categories of smart materials, whose modulus increases considerably in the presence of a magnetic field. These elastomers are prepared by dispersing magnetic micro-sized particles into a soft solid carrier medium. The main feature of these elastomers is that they change their elastic and damping properties quickly in the presence of a magnetic field. The change in properties, also known as the magnetorheological (MR) effect of MREs are dependent on various parameters such as type of matrix material, distribution of magnetic particles, additives, working mode, and strength of the applied magnetic field. Various studies have been conducted to improve the MR effect and seek the possibility to implement the MREs in different applications including but not limited to vibration absorbers, isolators, soft actuators, and sensors. The focus of this review is to present the recent progress of MREs including materials used, fabrication strategies, MR effect, and potential applications.

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Section: Vibration Absorbersmentioning

confidence: 99%

Recent progress of magnetorheological elastomers: a review

Bastola¹,

Paudel²,

Li³

et al. 2020

Smart Mater. Struct.

123

View full text Add to dashboard Cite

show abstract

“…In a different investigation on the boring process, Lawrence et al designed and fabricated an MRE damper consisting of 68% iron fillings with 30% silicon oil with the rest of the curing agents mixed thoroughly and cured for 24 h. Mean square deviation and ANOVA techniques used for the experiment which was conducted based on the Taguchi method for 27 run analysis optimizing different parameters including damper positions, coil direction and current applied, found to be successful in suppressing vibration up to 86.6% at 3 A current and coil winded perpendicular to the damper axis (Lawrance et al, 2019a). The dynamic characteristics of this boring tool have been studied to understand the effectiveness of MR damper to the system (Sam Paul et al, 2014a).…”

Section: Application In Boring Processmentioning

confidence: 99%

Application of smart fluid to control vibration in metal cutting: a review

Sarath¹,

Paul

2021

WJE

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Purpose A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of the service period of the cutting tool while machining. It is significant to provide a corresponding real-time varying damping to control this chatter, which directly influences accuracy and quality of productivity. This paper aims to review the literature related to the application of smart fluid to control vibration in metal cutting and also focused on the challenges involved in the implementation of active control system during machining process. Design/methodology/approach Smart dampers, which are used as semi-active and active dampers in metal cutting, were reviewed and the research studies carried out in the field of the magnetorheological (MR) damper were concentrated. In smart materials, MR fluids possess some disadvantages because of their sedimentation of iron particles, leakage and slow response time. To overcome these drawbacks, new MR materials such as MR foam, MR elastomers, MR gels and MR plastomers have been recommended and suggested. This review intents to throw light into available literature which exclusively deals with controlling chatter in metal cutting with the help of MR damping methods. Findings Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. In the past, many researchers have attempted to implement MR damper in metal cutting to control vibration and were successful. Various methods with the help of MR fluid are illustrated. Research limitations/implications A new cutting tool is always well-defined and sharp at the onset of metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of service period of cutting tool while machining. Application of MR damper along with the working methodology in metal cutting is presented, challenges met are analyzed and a scope for development is reviewed. Practical implications This study provides corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity. Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. Social implications This study attempts to implement smart damper in metal cutting to control vibrations. Originality/value It is significant to provide corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity.

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“…Due to the MREs' successful applications in above fields, they have been gradually employed in the mechanical machining. For instance, Lawrance et al [18] embedded an MRE in the boring tool to suppress the vibration caused by excessive suspension length in cutting process and experimental results illustrated the feasibility. Guan et al [19] prepared a hybrid magnetorheological material composed of the magnetorheological fluid and the MRE to a robot soft gripper, where a larger clamping force and a shorter response time were exhibited.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on vibration suppression for robotic milling using an MRE absorber

Zhao,

Tian,

Liu

et al. 2023

Smart Mater. Struct.

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During the robotic milling process, vibration is one of the main factors that affect the machining accuracy and surface quality due to the low stiffness of the robot structure. Intelligent material, magnetorheological elastomer (MRE), owns the features of adjustable stiffness, reversible and fast response, has been gradually used for vibration suppression. Therefore, to suppress the forced vibration for robotic milling, this paper used the principle of vibration absorption and combined it with MRE material to design a snubber. A series of excitation and milling experiments were carried out to evaluate its vibration attenuation characteristics. In the excitation experiment, sine signals with frequencies of 40 Hz, 42.02Hz and 60Hz with the same amplitude of 5N were applied to the MRE absorber. In the milling experiment, the dominant frequencies under speeds of 800RPM, 840RPM and 1200RPM were analyzed first. Then, the vibration mitigation characteristics of MRE absorber during robot milling of aluminum alloy were explored by adjusting the current. Experimental results showed that under the action of MRE absorber, the acceleration responses are suppressed effectively. In detail, after tuning the current, the amplitude and the root mean square of vibration acceleration in three directions of sinusoidal excitation could be suppressed by more than 19.23% and 7.35% correspondingly. The power spectral density value of the peak frequency could be reduced by more than 69.13%. In milling experiments, the MRE absorber also achieved certain vibration absorption effects. Furthermore, the surface roughness of the workpiece was also fallen by more than 16.51% which provides support for further engineering application in the field of robotic milling. Undoubtedly, the absorber needs further optimization to achieve better vibration suppression ability and a larger working bandwidth.

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Influence of magnetorheological elastomer on tool vibration and cutting performance during boring of hardened AISI4340 steel

Cited by 23 publications

References 15 publications

Recent progress of magnetorheological elastomers: a review

Recent progress of magnetorheological elastomers: a review

Application of smart fluid to control vibration in metal cutting: a review

Experimental study on vibration suppression for robotic milling using an MRE absorber

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