Prediction of cutting tool vibration and surface roughness in hard turning of AISI52100 steel

Abstract

The changing behavior of vibration signals with varying cutting parameters (cutting speed, feed rate and depth of cut) for turning hardened AISI52100 steel has been studied and reported. The vibration response of cutting tool in all three mutually perpendicular directions, namely, in feed Vx, radial Vy and, tangential Vz directions have been captured by mounting piezoelectric tri-axial accelerometer close to the cutting tool. Experiments are planned and conducted as per Central composite rotatable design of Surface response methodology. The second order multiple regression models are developed to correlate cutting parameters with vibration acceleration and surface roughness. The coefficient of regression R2 for all models is found close to 0.92 which shows that the developed models are reliable and provide an excellent explanation between the cutting parameter and the vibration of cutting tool within limits. The analysis of the results revealed that cutting conditions are having prominent and mixed type effect on vibration signals. The acceleration amplitude Vx, Vy and Vz increases with increase in cutting speed, and depth of cut. The vibration amplitude Vx, Vy and Vz initially increases as feed increases and, with further increase in feed, the vibration amplitude decreases. The surface roughness is highly influenced by the feed rate followed by cutting speed whereas the depth of cut was found less significant. The fluctuation in frequency is observed in all directions. However, the band of frequency remains within a certain range. Within selected cutting parameter range, the maximum acceleration amplitude is observed in frequency band of 4 kHz - 16 kHz.

Prediction of Surface Roughness in Turning Applying the Model of Nonlinear Oscillator with Complex Deflection

“…Using the aforementioned analytic solving procedure and the relations ( 27) and ( 28) we calculate the amplitude and frequency of vibration, according to (13)…”

“…As the cutting force depends on the feed value and the velocity it is expected that these parameters have an influence on the vibration property of the system and roughness of the cutting surface. Using the values given in Table 1 and relations (13) and (18), the amplitude and frequency of vibration of the workpiece-cutting tool system are calculated and shown in Table 2.…”

“…Thus, experiments are done for workpieces made of various materials such as Ti-6Al-4V [1,2], dry grey cast iron [3], Inconel 718 alloy [4], stainless steel [5][6][7], for AISI 5140 [8], and AISI 316L steel for biomedical purposes [9]. The roughness properties of the turning EN19 steel, cut with the coated carbide tool [10], AISID2 turning with minimal quantity of lubrication (MQL) [11], dry turning [12] and hard turning of AISI 52100 steel [13], and Haynes 263 and Inconel 718 superalloys turning with cryogenic cooling [14] have also been considered. The obtained results show that the roughness level differs for various workpieces and turning properties and parameters.…”

Surface Roughness Prediction in CNC Hole Turning of 3X13 Steel using Support Vector Machine Algorithm

“…Cutting velocity and depth of cut have a negligible effect on surface roughness. Nitin Ambhore et al [4] conducted experiments to investigate the effect of cutting speed, tool amount and cutting depth on surface roughness when turning AISI 52100 steel with a cutting piece marked CNMG120408-MF5. The testing process was conducted by RSM method based on CCD test matrix.…”

Experimental Investigation of Effect of Overhang Tool Length on Tool Vibration and Surface Roughness

“…Experimental results have shown that induced vibration has significant impact on surface roughness which can be used to control the finished surface of a work pieces during mass production. The changing behaviour of vibration signals with varying cutting parameters (cutting speed, feed rate and depth of cut) for turning hardened AISI52100 steel has been studied in [9]. Experiments are planned and conducted as per Central composite rotatable design of Surface response methodology.…”