Effect of Rheological Fluid Parameters on Tool Vibration During Boring of Hardened Steel

Abstract

In boring operations, tool vibration is a significant parameter which leads to poor surface finish, tool wear and damage of cutting tool. The relative dynamic motion between the cutting tool and work material induces vibration which accelerates tool wear, damage surface finish and produce irritating noise. In order to restrain tool vibration in metal cutting, it is necessary to develop and analyze suitable method which increases stability thereby improving cutting performance. The present investigation aims at developing a smart material controlled boring bar which will respond to an applied field with a dramatic change in rheological behavior. Magnetorheological fluid which was controlled by size of the particle, viscosity of fluid and positioning of rheological fluid is used as smart material in this paper. Magnetorheological fluid was developed and cutting experiments were conducted to arrive at a set of parameters that can reduce tool vibration and promote better cutting performance during boring of hardened AISI 4340 steel. From the results, it was observed that smart material controlled boring bar reduces tool vibration and also improves the cutting performance.