Study on the influence of magnetorheological fluid on tool vibration during end milling process

Paul, P. Sam; Kumar, Chandan; Joshua, Melvin; Vignesh, S.; Saravanan, S.; Varadarajan, A.

doi:10.1007/s40435-015-0214-x

Cited by 7 publications

(2 citation statements)

References 12 publications

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“…For end milling process, a novel MR damper was designed and fabricated which was convenient for machine tool setup as shown in Figure 17. A 70:30 (Fe:oil) weight ratio proved again to be more efficient in controlling vibration and superior for cutting performances (Paul et al, 2017a). Influenced by these studies, Kishor et al designed and developed MR damper which suppresses chatter even though it shows unusual noise at lower cutting speeds.…”

Section: Application In Milling Operationmentioning

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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Section: Application In Milling Operationmentioning

confidence: 99%

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

Sarath¹,

Paul

2021

WJE

Self Cite

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“…Te regression model was developed, optimization was performed using a genetic algorithm, and the nose radius showed a negative value during sensitivity analysis. Te author [13] stated that tool life, quality of machined products, and functional behavior are primarily afected by vibration. Studies have been conducted using magnetic rheological fuid dampers to suppress vibration using AISI 4340 steel with 45HRC indexable inserts on milling machines.…”

Section: Introductionmentioning

confidence: 99%

A Hybrid Nondominant-Based Genetic Algorithm (NSGA-II) for Multiobjective Optimization to Minimize Vibration Amplitude in the End Milling Process

Gopal,

Gutema,

Lemu

et al. 2024

Advances in Materials Science and Engineering

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Aluminium is a noncorrosive, lightweight material used to fabricate parts for the aerospace, automobile, and construction industries. Due to the low-temperature resistance, more heat is generated. At the same time, in machining, tremendous efforts are taken to keep friction and chatter to a minimum and to attain better quality and perfect output, and also more attention is required while selecting the machining process parameters. Spindle speed, rate of feed, radial and axial depth of cut, and radial rake angle of the tool are the parameters utilized to machine aluminium 6063 using the HSS tool on CNC milling to estimate spindle and worktable vibration using a prediction model. In this study, the design of the experiment of the response surface methodology approach is used to create a second-order statistical equation for experimentation with the Design-Expert v12 software. The performance characteristics are analyzed using the ANOVA method. The spindle speed achieved the lowest vibration between 2000 and 3000 rpm. Next, axial and radial depths were the most vibration-affecting parameter compared to the rate of feed and radial rake angle of the tool. To find the best feasible response, the nondominant sorting genetic algorithm II (NSGA II) approach was trained and tested using MATLAB software. Using a Pareto-optimal technique, the optimum worktable vibration ranged from 0.00284 to 0.00165 mm/s2, whereas the spindle vibration ranged from 0.02404 to 0.01336 mm/s2. The predicted values were found to be in an excellent argument when Pareto-optimal solutions are used.

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