Optimization of cutting tool geometry and machining parameters in turning process

Saravanamurugan, S.; Sundar, B. Shyam; Pranav, R. Sibi; Shanmugasundaram, A.

doi:10.1016/j.matpr.2020.10.246

Cited by 7 publications

(4 citation statements)

References 12 publications

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“…These selected tool overhang lengths represented the ratio (L/D-tool overhang length/diameter of the boring bar), where tool overhang is smaller than 4D/5D (5 × diameter of the boring bar) for L e of 30 mm (3.75D) as well as larger than 4D/5D for L e of 48 mm (6D). As demonstrated in the state-of-the-art research [30], a tool overhang value of more than 4D/5D is often considered critical from the standpoint of chatter initiation in the machining process, which in turn negatively influences the resulting workpiece qualities, such as surface roughness or dimensional accuracy [31]. The cutting parameters used in the experiment are shown in Table 2.…”

Section: Cutting Testsmentioning

confidence: 99%

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

Vopát,

Kuruc,

Pätoprstý

et al. 2024

Machines

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The turning of small-diameter deep holes is usually critical when the process of machining is unstable and the use of a special boring bar is often necessary. This paper is focused on the influence of cutting speed with a combination of cutting conditions such as feed and tool overhang on chatter marks, surface roughness and roundness of machined holes. In the experiment, two types of tool material for indexable boring bars were used, namely cemented carbide and steel. These are a group of boring bars used for the internal turning of holes of small diameters with indexable cutting inserts. Monolithic carbide boring bars are already used for internal turning of holes of even smaller diameters. Uncoated turning inserts made of cermet were used. The cutting tests were performed on the DMG CTX alpha 500 turning center. In the case of the steel boring bar, decreasing the cutting speed really led to an increase in the quality of the surface roughness and reduced the formation of chatter marks and large chatter marks. The cemented carbide boring bar also followed a similar trend, but it should be noted that the overall effect was not so great. This means that increasing the cutting speed makes the cutting process less stable and, vice versa, lower values of cutting speed reduce the formation of chatter marks and the related deterioration of the surface quality. The occurrence of chatter is directly related to the increase in the surface roughness parameters Ra and Rz of the machined surface. It can be stated that the dependence of roundness deviations on cutting speed values has a similar character to the results of the measured surface roughness values. Therefore, if the cutting speed is increased, it will make the cutting process less stable; this is also indirectly reflected in larger roundness deviations. However, it is necessary to state that this phenomenon can be observed in turning holes with small diameters using the steel boring bar, where the unstable cutting conditions materialized in the form of chatter marks.

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Section: Cutting Testsmentioning

confidence: 99%

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

Vopát,

Kuruc,

Pätoprstý

et al. 2024

Machines

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“…Statistical approaches were also used to determine the influence of the cutting parameters. By reducing the real part of the frequency response function, which measures how a cutting tool responds to a harmonic force, Saravanamurugan et al (2021) optimised cutting tool shape and cutting parameters of the turning process. Zhuang et al (2018) established an analytical model to predict the cutting forces during oblique turning.…”

Section: Introductionmentioning

confidence: 99%

Optimization and finite element modeling of orthogonal turning of Ti6Al4V alloys: A comparative study of different optimization techniques

Sumesh¹,

Ramesh²

2023

10.5267/j.esm

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The main goal of this research is to compare the various optimization strategies (Response Surface Methodology, Taguchi, and Teaching Learning Based Optimization) for orthogonal turning of Hard to Machine materials. The workpiece material in this work is Ti6Al4V alloys. After selecting cutting speeds in the High-Speed Machining range, orthogonal turning tests are performed on the material for a specific combination of machining parameters – Depth of Cut, Cutting Speed, and, Feed Rate. A Lathe Tool Dynamometer is used to record the cutting forces from the trials. After combining Johnson Cook Material and Damage models, a comprehensive Finite Element Model is created to model the Orthogonal Turning of Ti6Al4V alloys. Experiments conducted previously validate the developed model. Three different strategies, namely RSM, Taguchi, and TLBO, were used to optimise machining parameters for minimal Cutting Force. The approaches are compared for the best combination of machining parameters and the best Cutting Force value. Analysis of Variance is used to study the impact of machining factors on Cutting Force.

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“…For example, a tool holder with enhanced dynamical stiffness and damping ratio is developed for chatter reduction in face milling [39]. Optimization of cutting tool geometry and machining parameters is investigated for the turning process by Saravanamurugan et al [40].…”

Section: Introductionmentioning

confidence: 99%

Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

Hayati

Golmohammadi²,

Valitabar³

et al. 2023

Preprint

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In this study, a milling tool with variable mass and stiffness is developed for chatter reduction. The proposed milling tool is hollow with a solid core threaded inside it. As the core is screwed in or out of the tool body, the equal mass and stiffness of the tool are changed. Therefore, the tool's frequency response function (FRF) is changed to affect the stability lobe diagram (SLD) position. Moving the SLDs can stabilize an unstable cutting process. With respect to the FRFs obtained from modal test, the idea is proven using an experimental and analytical approach. The optimum core position for every spindle speed is also presented. The developed tool stability is then investigated in a realistic cutting condition. The cutting process sound analysis and surface finish visual inspection results reveal the performance of the proposed system in chatter reduction of a slender milling tool.

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Optimization of cutting tool geometry and machining parameters in turning process

Cited by 7 publications

References 12 publications

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

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

Optimization and finite element modeling of orthogonal turning of Ti6Al4V alloys: A comparative study of different optimization techniques

Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

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