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Machining 3
Machining 3
Mineral-oil based
Synthetic
Bio-degradable
Bio-resistant
Soaps
Defoamers
Sulphur
Chlorinated
Mist
mostly water based coolants
Flood
Coolant or Lubricant?
Temperature
Cutting speed
Type of machining operation
Method of application
brush (manual)
mist
flood
Vibration
Forced
periodic applied force
from a motor or gear drive
Self-excited
interaction of dynamics of chip removal process
and structural dynamics of machine tool
Chatter
Results from vibration
Tool bounces in and out of the workpiece
Glacial Chatter
Chatter Types
Regenerative (f < 1000 Hz)
when a surface undulation
previously produced causes a
cutting force variation
Chatter Types
Self-excited vibration (1000 < f < 10,000 Hz)
negative slope of the shear-stress vs. temperature
(t vs. q) relationship
force components provide positive instead of
negative damping
10
Vibration Elimination
Stiffer machines
Tuned dampers
Active control
Support workpiece rigidly
Minimize cutter overhang
Modify tool and cutter geometry
Change process parameters
speed, feed, depth of cut, cutting fluid
11
components
Ribs
No ribs
No slot
Configuration-1
Configuration-2
Slot
Configuration-3
Configuration-4
Different configurations
Max def
Deformation(m)
1.00E-07
def_x
8.00E-08
def_y
6.00E-08
def_z
4.00E-08
2.00E-08
0.00E+00
1
Configuration no.
13
Frequency(Hz)
3600
3300
3000
2700
2400
2100
1800
1500
1200
900
600
300
0
with ribs
no ribs
Prototype-II frequency
more than prototype-I
No ribs case higher
frequency more than
with ribs case
first 6 modes critical
With ribs case better
than others, supported by
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
frequency response curve
Mode no.
15
Summary
Chip formation process
Cutting fluids
Vibration and chatter
18