Enhancement of Turning Process using Vibration Signature Analysis

Abstract

Analytical and experimental vibration analyses are conducted for a lathe system to detect the possibility of faults and to develop an accurate cutting process. The data acquisition system utilized for this purpose processes the analog input from the manufacturing system and displays the response in both the real time and frequency domains. The vibration signatures for different arrangements are recorded to determine the dynamic characteristics of the system, which includes workpieces, tool, and lathe components. These vibration signatures were analyzed to determine causes of inaccuracy in the manufacturing process and faulty components. In this study, two major problem-causing sources were identified using vibration analysis for the system under different operating conditions. In addition to the identified problems, the phenomena of cutting tool chatter with various intensities was examined and recorded during testing. In this study the best possible operating conditions for a specific turning process were determined using vibration analysis. Problem-causing components for several case studies (different speeds, feed rates, and tool lengths) were identified and guidelines for improving a typical manufacturing process were recommended.