Tool Vibration Research Articles

Research on Hybrid Vibration Sensor for Measuring Downhole Drilling Tool Vibrational Frequencies

The vibration parameters during drilling play a critical role in enhancing drilling speed and ensuring safety. However, traditional downhole vibration sensors face limitations in their power supply methods, hindering widespread adoption. To address this challenge, our research introduces a novel solution: a hybrid downhole vibration sensor (HDV-TENG) utilizing triboelectric nanogenerators. This sensor not only enables the measurement of low- to medium–high-frequency vibrations using self-power but also serves to energize other downhole devices. We utilized a self-constructed vibration simulator to replicate downhole drilling tool vibrations and conducted a comprehensive series of sensor tests. The test results indicate that the frequency measurement bandwidth of the HDV-TENG spans from 0 to 200 kHz. Especially, the measurement errors for vibrations within the low-frequency range of 0 to 10 Hz and the high-frequency range of 10 to 200 k Hz are less than 5% and 8%, respectively. Additionally, the experimental findings regarding load matching demonstrate that the HDV-TENG achieves an output power level in the milliwatt range, representing a significant improvement over the output power of traditional triboelectric nanogenerators. Unlike traditional downhole vibration measurement sensors, HDV-TENG operates without requiring any external power supply, thereby conserving downhole space and significantly enhancing drilling efficiency. Furthermore, HDV-TENG not only offers a broad measurement range but also amplifies output power through the synergy of a triboelectric nanogenerator (TENG), piezoelectric nanogenerator (PENG), and electromagnetic power generator (EMG). This capability enables its utilization as an emergency power source for other micropower equipment downhole. The introduction of HDV-TENG also holds considerable implications for the development of self-powered underground sensors with high-frequency measurement capabilities.

Влияние динамических характеристик процесса резания на шероховатость поверхности детали при токарной обработке

Introduction. The formation of the surface of a part when processing it on a metal-cutting machine is based on properly selected cutting modes. Complex methods of ensuring the specified quality of the part surface also take into account the tool geometry, its condition, and include corrections for tool deviation from the trajectory set by the CNC system under the influence of kinematic disturbances and spindle wavering. Subject. The paper analyzes the relationship between cutting modes and dynamic characteristics of the turning process, and its mapping into surface roughness. The aim of the work is to evaluate the influence of technological cutting modes taking into account the vibration activity of the tool on the roughness of the machined surface by means of simulation modeling. Method and methodology. Mathematical simulation of the dynamics of the cutting process is given, on the basis of which a digital simulation model is built. A methodology of using the simulation model for determining optimal cutting modes and predicting surface roughness taking into account tool vibrations is proposed. By means of experiments and analysis of the frequency characteristics of tool vibrations, the created model is validated, parameters of the cutting forces model subsystem and dynamic tool subsystem are specified, and geometrical topologies of the part surface are constructed. The calculated cutting forces are compared with experimental forces, and similar patterns and levels of characteristics are observed. An assessment of the optimality of the selected cutting modes is proposed based on the analysis of the tool vibration spectrum relative to the workpiece and the results of the numerical model simulation. Results and Discussion. A comparison of the results of digital modeling of the geometrical surface of the workpiece and the real surface obtained during the field experiment is given. It is shown that the roughness of the real surface obtained by machining with constant cutting modes varies relative to the surface roughness of the simulation model within the limits of not more than 0.066 µm.

Cylinder accuracy analysis of tangential turning of disk-like workpieces with increased cutting speed

Tangential turning, a precision high-speed finishing procedure, is crucial for achieving superior surface quality and dimensional accuracy in cylindrical workpieces. This advanced machining technique leverages tangentially applied cutting forces to minimize tool deflection and vibration, thereby enhancing the surface integrity of the final product. Despite its advantages, tangential turning poses challenges in maintaining cylindrical accuracy, necessitating a thorough investigation of cylindrical error. Cylindrical error, the deviation of the machined surface from a perfect cylinder, significantly impacts the functional performance of precision components. Factors such as tool wear, machine dynamics, and thermal effects can induce these errors, demanding comprehensive studies to optimize process parameters and tool paths. By thoroughly analyzing cylindrical error, manufacturers can refine tangential turning processes, ensuring high precision and consistency in high-speed finishing operations. This research underscores the importance of precision error analysis in advancing manufacturing capabilities and achieving stringent quality standards. Cylindrical accuracy is analyzed using the full factorial experimental design methodology to carry out practical cutting experiments, where the cutting speed, feed, and depth of cut were the altered variables. The cylindricity error, peak maximum departure, their ratio, and coaxiality are measured and analyzed. The main effect analysis and detailed study are elaborated using the determined equation. It is found that decreasing the studied parameters is advisable if increasing cylinder accuracy is needed.

AiroTouch: enhancing telerobotic assembly through naturalistic haptic feedback of tool vibrations.

Teleoperation allows workers to safely control powerful construction machines; however, its primary reliance on visual feedback limits the operator's efficiency in situations with stiff contact or poor visibility, hindering its use for assembly of pre-fabricated building components. Reliable, economical, and easy-to-implement haptic feedback could fill this perception gap and facilitate the broader use of robots in construction and other application areas. Thus, we adapted widely available commercial audio equipment to create AiroTouch, a naturalistic haptic feedback system that measures the vibration experienced by each robot tool and enables the operator to feel a scaled version of this vibration in real time. Accurate haptic transmission was achieved by optimizing the positions of the system's off-the-shelf accelerometers and voice-coil actuators. A study was conducted to evaluate how adding this naturalistic type of vibrotactile feedback affects the operator during telerobotic assembly. Thirty participants used a bimanual dexterous teleoperation system (Intuitive da Vinci Si) to build a small rigid structure under three randomly ordered haptic feedback conditions: no vibrations, one-axis vibrations, and summed three-axis vibrations. The results show that users took advantage of both tested versions of the naturalistic haptic feedback after gaining some experience with the task, causing significantly lower vibrations and forces in the second trial. Subjective responses indicate that haptic feedback increased the realism of the interaction and reduced the perceived task duration, task difficulty, and fatigue. As hypothesized, higher haptic feedback gains were chosen by users with larger hands and for the smaller sensed vibrations in the one-axis condition. These results elucidate important details for effective implementation of naturalistic vibrotactile feedback and demonstrate that our accessible audio-based approach could enhance user performance and experience during telerobotic assembly in construction and other application domains.

Experimental investigations of the effects of bending vibrations resonance modes on penetration into granular materials

Inspired by the bending vibration observed in the biological locomotions such as those found in snakes, horned lizards, and sandfish, we have developed a novel vibro probe utilizing bending resonance modes to study the bending vibration effects in assisting penetration into granular materials. This approach contrasts with traditional probes that rely on longitudinal vibrations for penetration. This newly developed probe was used to experimentally investigate the impact of bending vibration in reducing the required penetration force and enhancing the penetration process within granular materials such as lunar or Martian regolith. The bending vibrations were excited by thin piezo patches attached to the probe’s machined surface without increasing the probe’s outside diameter. This simple mechanism enables pushing the whole probe inside the granular materials. Experimental modal analysis was employed to determine the resonance frequencies of the probe. Subsequently, the probe was pushed into granular materials, both with and without the bending vibrations, by a linear actuator. Experimental results indicated that employing bending vibration in one direction led to a reduction in penetration force by up to 27% while utilizing two directions resulted in a reduction of up to 42%. Additionally, when the probe stopped penetrating the soil due to insufficient axial force, bi-directional bending vibration proved more effective in swiftly fluidizing the surrounding soil. These findings highlight the efficacy of bending vibrations in compact subsurface drilling tools.

Investigation of hybrid ultrasonic machining process of Nomex honeycomb composite using a toothed disc cutter

Nomex honeycomb composite (NHC) has been increasingly used in the automotive, aerospace and defence applications due to its excellent thermal and mechanical properties. Its complex cellular hexagonal thin-walled configuration along with heterogeneous, soft and brittle nature pose substantial processing defects such as burr formation, tearing of walls, surface roughness, dimensional inaccuracy and low machining quality during conventional machining (CM). These surface defects have a substantial influence on the operating life and functional performance of its sandwiched structural members. Hybrid ultrasonic vibration assisted machining (HUSVAM) technology has been introduced to overcome such limitations. For an in depth research on HUSVAM of NHC using ultrasonic toothed disc cutter (UTDC), three dimensional finite element model was developed and experimental validation was carried out. The numerical simulation and experimental results were found to be in good agreement with one another. The influence of various machining parameters including the ultrasonic tool vibration amplitude (UTVA), feed rate (FR), depth of cut (DoC) and spindle angular speed (SAS) on NHC cutting forces, chip formation and surface quality was investigated using both HUSVAM and CM techniques. Furthermore, stresses, deformation and forces near tool-workpiece interaction along with the surface topography and morphologies were also analysed and compared for various operating conditions. A reduction in the cutting forces was found with the increase of SAS and UTVA (up to 65.47 % and 65.74 %, respectively). Although, the cutting forces were observed to increase by increasing the DoC and FR (up to 159.45 % and 126.33 %, respectively). DoC has a greater impact on the cutting forces among all machining parameters according to 4 levels, 4 factors (L16) orthogonal experiments based on Taguchi method. The results show that the chip formation and machining quality of NHC core can be improved with HUSVAM technique using UTDC. HUSVAM also reduced the cutting forces (up to 73 %) compared to CM. The ultrasonic toothed disc cutter generated large number of burr with very short length, no tearing defects and no uncut fibers as observed from scanning electron microscopy of NHC hexagonal cell structure, walls and triple points. A burr formation of less than 10 % was realized during HUSVAM of NHC cores for Fx≤3N, while it was found up to 20 % if Fx>3N, compared to at least 40 % during CM. The finite element model developed can be used to investigate the influence of HUSVAM on modern difficult to machine materials for enhanced surface quality.

Effect of metallic substrate and rubber elastic materials over passive constrained layer damping on tool vibration during boring process

Tool vibration is a key factor that affects surface finish, generates noise, and reduces the tool life during conventional boring because of the excessive overhanging length of the tool holder. The interaction between the dynamics of the machine tool and the boring process led to progressive vibration. The creation of appropriate mechanisms in reducing tool vibration will help manufacturing industries to become more productive. In this research, in order to control vibration in the overhanging boring bar, a passive vibration control method was employed. Constrained layer dampers consist of boring bar, substrate, and elastic materials and it is used to minimize tool vibration produced during boring operation. The investigation utilized computational analysis through the ANSYS Workbench platform, employing key parameters such as the overhanging length of the tool holder (100, 150, and 200 mm), substrate material (aluminum, brass, and copper), and elastic material (Nitrile rubber, Natural rubber, and polyurethane). A comprehensive series of 27-run boring experiments were conducted to assess the impact of the constrained layer damper on tool vibration and cutting properties. The results of the study revealed remarkable improvements in various performance metrics. The constrained layer damper demonstrated an impressive 98% reduction in tool vibration, signifying its efficacy in dampening vibrational forces during the boring operation. Furthermore, a substantial 83% decrease in surface roughness was observed, indicating enhanced machining precision and surface finish. The constrained layer damper also exhibited a noteworthy 97.5% reduction in tool wear, highlighting its ability to significantly prolong tool life under challenging machining conditions.

Coupling effect of machine tool dynamic characteristics and cutting conditions on the cutting process vibration and high-speed micro-planing surface mid-frequency waviness

In addition to the dynamic characteristics of the machine tool, cutting conditions significantly influences the vibration of the cutting system and mid-frequency waviness of the workpiece surface in ultra-precision machining (UPM). In this work, the effects of cutting conditions on machining vibration and surface waviness were investigated by high-speed micro-planning experiments. The origin of vibration and waviness were elucidated by frequency-domain processing of the vibration signal and surface waviness analysis. The dynamic characteristics of machine tool are determined using modal test and analysis. The results revealed that the cutting force has different contributions to the workpiece vibration and tool vibration. In the time domain, distinct differences can be found in stability and attenuation of various waviness components. The divergent effects of cutting force components in different vibration forms are confirmed through a novel cutting force model of micro-planing. The investigation can further reveal the formation mechanisms of cutting system vibration and surface waviness during the micro-cutting process, which can provide practical guidance for suppressing mid-frequency waviness on machined surfaces.

Prediction of Surface Roughness Components in Turning with Single Point Tool—Measurement of Tool Edge Contour and Prediction of its Position During Cutting—

Surface roughness is affected by the tool geometry, feed rate, overcutting by built-up edge, and tool vibration in the depth of the cut direction. However, dividing the roughness value into each component is difficult. Therefore, a new prediction method for the position of the tool contour on the roughness curve is proposed to divide the measured roughness value into components. This proposed method consists of two processes. In one, the roughness curve is divided into the roughness curve formed during each revolution of the work material regardless of the clarity of the feed marks. The other is the process that predicts the vertical position of the tool contour. If the vertical position of the tool contour can be predicted, the vibration and overcutting components of roughness can also be predicted. In this study, the transition of roughness components such as the theoretical roughness, vibration width, and overcutting is studied with the increase in the cutting distance in the turning of chromium molybdenum steel, JIS SCM435. When supplying a 10% emulsion mist, the measured Rz is smaller than that of the dry condition. In both the dry and mist supply conditions, the measured Rz increases from the beginning of cutting then decreases and then increases again with the increase in the cutting distance. The largest component of the total roughness in both the dry and mist supply conditions is the theoretical roughness Rth. The ratio ranges between 50.3% and 78.7%. Regardless of the cutting conditions, the vibration width in the depth of the cut direction is relatively constant. The overcutting slightly increases after the start of cutting, then decreases when the maximum contact length exceeds approximately 0.1 mm. The proposed method verifies the ratio of the surface roughness components and is an effective method for improving the surface roughness.

Fundamental investigation on the time-variance of process stability

Disturbance factors, such as self-excited tool vibrations, limit the performance of modern machining processes and thus restrict the quality, productivity and sustainability of industrially manufactured components. The dynamic process stability is subjected to significant variances especially at the beginning of the tool life. To precisely quantify these variances, series of milling tests were conducted and analyzed using tools made of high speed steel (HSS) and cemented carbide for the machining of EN AW-7075. In all test series, a critical initial decrease of the stability limit was detected directly at the beginning of the tool life. In the following, a significant increase and subsequent almost constant stability limit was observed. In the case of the HSS cutters the achieved stability limit exceeded the initial level substantially. An increase in the process forces and flank wear was also measured over tool life but the progression cannot directly explain the extend and characteristics regarding the stability limit. The findings described have a considerable impact on the appropriate design of manufacturing processes and experiments to determine the dynamic stability of cutting operations.

Semi-active control of tool vibration in hard turning using magnetorheological fluid damper

Semi-active control of tool vibration in hard turning using magnetorheological fluid damper

Evaluation of Hand-Arm Vibration Syndrome Owing to Nerve Conduction Study and Cumulative Exposure Index-A 2.5-Year Cohort Study.

This study aims to clarify the relationship between peripheral neuropathy in hand-arm vibration syndrome and cumulative exposure index. 68 participants without symptoms were surveyed. The participants were divided into three groups based on past and current vibration exposure (VE). Comparison among groups according to past VE showed that the median and ulnar sensory nerve conduction velocities and median sensory nerve action potential (SNAP) amplitude were significantly lower in past high and low exposure groups than in the past nonexposure group. Comparison among groups according to current VE showed that the median and ulnar SNAP amplitudes were significantly lower in the current high exposure group than in the current low or nonexposure group. Vibration tool handlers have potential peripheral nerve lesions at a certain stage without subjective symptoms of the finger.

Experiment Study of Deformable Honeycomb Triboelectric Nanogenerator for Energy Collection and Vibration Measurement in Downhole

Downhole drilling tool vibration measurement is crucial for drilling exploration safety, so real-time monitoring of vibration data is required. In this research, a honeycomb triboelectric nanogenerator (H-TENG) capable of adapting to various downhole environments is proposed. It can measure the frequency of downhole drilling equipment’s vibrations and transfer mechanical energy to electrical energy for use in powering other low power downhole meters. In order to preliminarily verify the possibility of sensors used for vibration measurement of downhole drilling tools, we built a simulated vibration platform to test the sensing performance and vibration energy collection performance of H-TENG. According to the testing results, the measurement range of vibration frequency and amplitude are 0 to 11 Hz and 5 to 25 mm, respectively, and the corresponding measurement errors are less than 5% and 6%, respectively. For vibrational energy harvesting, when four sensors are wired in series with a 107 resistance, the maximum power is approximately 1.57 μW. Compared to typical methods for measuring downhole vibration, the honeycomb triboelectric nanogenerator does not need an external power source, it has greater reliability and output power, and it can vary its shape to adapt to the complicated downhole environment. In addition, the H-TENG can be combined freely according to the diameter of the drill string, and even if one sensor unit is damaged, the other units can still be used normally.

A New Design of Vibration Damping Structure for Positive Displacement Motor

Positive displacement motor (PDM) is a downhole power drilling tool, and the bottom of the drilling tool is directly connected to the drill bit. During the drilling process, the drilling tool will be directly affected by the impact load caused by the drill bit breaking the rock. Severe vibration can easily cause drill tool bearings to break and fail, threads to trip and other problems. The new PDM vibration damping structure uses wear-resistant and heat-resistant metal rubber instead of disc springs as energy-absorbing materials, and designs a "keyway type" vibration damping structure; a two-degree-of-freedom "spring - mass" model is established based on actual working conditions. , determine the basic size of the metal rubber pad based on the metal rubber stress-strain curve, and bring it into the drilling tool dynamics equation to verify that the stiffness and damping parameters of the metal rubber pad will not resonate; finally, compare the drilling conditions under different excitations in the dynamics simulation software The amount of impact the tool receives. Finally, the dynamics simulation of the new vibration-damping drilling tool under different frequency excitations was carried out in Adams simulation software, and it was concluded that in the common working environment of 6-15 Hz, the new vibration-damping drilling tool can effectively reduce the stress on the drilling tool. Impact force, the new vibration-damping drilling tool can reduce the impact force by about 40% when excited at 12 , 15 Hz . The conclusions drawn from the study have reference value for the development of long-life drilling tools and the design of drilling tool vibration damping structures.

Prediction of Surface Topography in Robotic Ball-End Milling Considering Tool Vibration

Because of their low cost, large workspace, and high flexibility, industrial robots have recently received significant attention in large-scale part machining. However, due to the stiffness limitations in robot joints and links, industrial robots are prone to vibration during milling processes, which leads to poor surface topography. In robotic milling processes, it remains challenging to simulate the surface topography accurately. This paper presents a mathematical model of surface topography combined with the effects of process parameters and tool vibrations in robotic milling. In this method, the kinematic trajectory of the cutting edge is first calculated by considering the cutter geometry, tool eccentricity, tool orientation, and redundancy angle. After that, the posture-dependent dynamic characteristics of the robotic milling system are predicted using an inverse distance-weighted approach. Then, a dynamic model of the robotic milling system is constructed for calculating tool vibration displacements. Finally, the kinematic model of cutting edges is modified using Z-map to incorporate the obtained vibration displacements into the sweep surfaces. In addition, milling experiments are carried out to verify the effectiveness of the proposed method, showing a good agreement between predicted and measured surface roughness. Furthermore, the findings offer valuable insights into the impact of process parameters and robot posture on surface quality.

Analysis, modelling and optimization on tool vibration in machining of nitronic 60 with SiAlON ceramic tool

ABSTRACT The study investigates tool vibration during finish turning of austenitic steel (Nitronic 60) using a new-generation SiAlON ceramic cutting insert under dry conditions. Three parameters—cutting speed, depth of cut, and feed—are varied across three levels each. Experimental results are analyzed using ANOVA, response surface methodology (RSM), and desirability function approach. Depth of cut is found to be the main factor influencing tool vibration, with cutting speed exacerbating tool wear. A regression model yields a high correlation coefficient (R-square = 0.93) with low error percentage (6.05%). Optimization via RSM suggests machining conditions of cutting speed 100 m/min, depth of cut 0.1 mm, and feed 0.05 mm/rev for optimal results. The study proposes the use of SiAlON ceramic tools as an effective alternative to costly CBN tools for finish turning difficult-to-machine materials, offering practical industrial implications.

Investigation on the Surface Integrity of 40Cr Steel Machined by Rotary Ultrasonic Flank Milling.

Rotary Ultrasonic Machining (RUM) stands as a crucial method for machining hard and brittle materials. However, for machining hard-to-machine metal, it continues to face many challenges due to the complex vibration of the milling tool. Flank milling is an efficient method for machining complex parts, such as blisks and impellers, which have been widely used in aerospace field. However, current research is more focused on rotary ultrasonic end milling. In this context, we will study the surface integrity of rotary ultrasonic flank milling 40Cr steel using a self-developed RUM system. We delve into exploring the impacts of tool vibration on surface morphology, residual stress, and micro-hardness of the workpiece under various process parameters. The experimental findings reveal that rotary ultrasonic flank milling, in contrast to traditional flank milling techniques, significantly diminishes the surface roughness by about 40%. The reasons for the reduction of surface roughness are analyzed from the point of view of the cutting force. The surface roughness appears to be notably linked to both the average cutting force and the frequency domain characteristics. In addition, the experimental results indicate that rotary ultrasonic flank milling demonstrates the capacity to elevate the micro-hardness of the machined surface.

Elliptical vibration chiseling: a novel process for texturing ultra-high-aspect-ratio microstructures on the metallic surface

Highlights Elliptical vibration chiseling is proposed based on a game-changing process principle for the high-efficient texturing of ultrahigh-aspect-ratio surface microstructures. Uniformed microstructures with an aspect ratio of 2–12 in the spacing scale of 1–10 μm have been successfully fabricated using elliptical vibration chiseling. The developed process model of elliptical vibration chiseling has been verified by the measured results of the microstructures’ geometric parameters. An inclined elliptical trajectory of tool vibration is more suitable for elliptical vibration chiseling than the standard elliptical trajectory. The deterministic process effects on the surface generation of microstructure in elliptical vibration chiseling have been demonstrated.

Multi-Objective Optimization of the Inconel 718 Turning Parameters Using MARCOS–Based Taguchi S/N ratio

Nickel-based alloys, such as Inconel 718, are widely used in space technology, rocket engines, nuclear reactors, petrochemicals, submarines, power plants, and other applications. It is classified as a challenging material to process due to its strong mechanical properties, low thermal conductivity, and other characteristics. The main objective of this work is to determine the optimal cutting parameters for turning Inconel 718 using a coated carbide tool, with the aim of reducing cutting tool vibration, minimizing surface roughness, and maximizing material removal rate. This is achieved by employing the Measurement of Alternatives and Ranking according to Compromise Solution technique (MARCOS) coupled with Taguchi's signal-to-noise ratio. The results have demonstrated that the configuration of the cutting parameters for achieving the aforementioned objectives is as follows: r = 0.8 mm, Vc = 70 mm/min, f = 0.08 mm/rev, and ap = 0.3 mm.

Machining mechanism of metal glass cutting based on ultrasonic vibration tool path

Machining mechanism of metal glass cutting based on ultrasonic vibration tool path