Improving the Performance of Steel Machining Processes through Cutting by Vibration Control.

Mihaela Oleksik,Mădălin Tomescu,Valentin Petrescu,Dan Dobrotă

doi:10.3390/ma14195712

Abstract

Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the improved construction version. In the first stage of the research, an analysis was made of the vibrations that appear in the cutting process when using the two types of tools. Vibration analysis considered the following: use of the Fast Fourier Transform (FFT) method, application of the Short-Time Fourier-Transformation (STFT) method, and observation of the acceleration of vibrations recorded during processing. After the vibration analysis, the roughness of the surfaces was measured and the parameter Ra was taken into account, but a series of diagrams were also drawn regarding the curved profiles, filtered profiles, and Abbott–Firestone curve. The research showed that use of the tool that is the improved constructive variant allows accentuated reduction of vibrations correlated with an improvement of the quality of the processed surfaces.

Highlights

Most parts in the machine building industry are made by using certain machining processes by cutting
Experimental research was conducted in two distinct stages: in the first stage, the vibrations that occurred during the cutting process were measured; in the second stage, measurements were made regarding the roughness of the processed surfaces
The analysis of the spectrograms shows that, at the end of the machining process, the amplitude of vibrations decreases substantially compared to the beginning of the machining process, both in the Z and Y direction when using tool T02 but remains at considerably higher values when using tool T01. This can be explained by the fact that the use of the T02 tool allows for damping of vibrations that may occur in the cutting process

Summary

Introduction

Most parts in the machine building industry are made by using certain machining processes by cutting Under these conditions, it is necessary to optimize the machining processes by cutting, so as to achieve a reduction in manufacturing costs and determine an increase in the life of the products made. It is necessary to optimize the machining processes by cutting, so as to achieve a reduction in manufacturing costs and determine an increase in the life of the products made In this context, it is necessary to develop new cutting tools with superior characteristics or better performance than the existing ones. The cost of tools can be associated with the cost of manufacturing tools, and with their durability, which influences the productivity of processing, and the quality and accuracy of processed surfaces [1,2]. The surface quality of a workpiece is given, in generally accepted terms, by the surface roughness, the most common being the average roughness Ra [3,4]

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