Low Cost Vibration Measurement and Optimization during Turning Process

Abstract

During machining any material, vibrations play a major role in deciding the life of the cutting tool as well as machine tool. The magnitude acceleration of vibrations is directly proportional to the cutting forces. In other words, if we are able to measure the acceleration experienced by the tool during machining, we can get a sense of force. There are many commercially available, pre-calibrated accelerometer sensors available off the shelf. In the current work, an attempt has been made to measure vibrations using ADXL335 accelerometer. This accelerometer is interfaced to computer using Arduino. The measured values are then used to optimize the machining process. Experiments are performed on Brass. During machining, it is better to have lower acceleration values. Thus, the first objective of the work is to minimize the vibrations. Surface roughness is another major factor which criterion “lower is the better” applies. In order to optimize the values, a series of experiments are conducted with three factors, namely, tool type (2 levels), Depth of cut (3 levels) and Feed are considered (3 levels). Mixed level optimization is performed using Taguchi analysis with L18 orthogonal array. Detailed discussion of the parameters shall be given in the article.

Evaluation of Chip Formation Mechanisms in the Turning of Sintered ZnO Electro-Ceramics

“…The vibrational feedback obtained from 0.2 mm/rev signifying the higher cutting force in play is quite evident in Figure 5; however, the requirement for the cutting force was lower for the higher feed velocities in the time domain to complete the respective turning operation on a sintered ZnO ceramic. In short, the turning operations finished faster with higher feed velocities and the process was completed in a shorter time frame at 0.2 mm/rev as compared to 0.1 mm/rev, which is in line with the projections from the accelerometer data related to machining processes [8,11,17].…”

“…These can be examined for fault detection and surface integrity analysis during the machining run. The accelerometer has also found similar applications in the characterization and optimization of metal cutting in the turning processes [8]. Roy et al [9] successfully employed an accelerometer coupled to a machining unit to corelate the toolworkpiece contact before commencing precision machining.…”