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Sivasakthivel Paper
Sivasakthivel Paper
DOI 10.1007/s00170-010-2872-3
ORIGINAL ARTICLE
Received: 16 March 2010 / Accepted: 28 July 2010 / Published online: 10 August 2010
# Springer-Verlag London Limited 2010
[12] focused on the presentation of a time domain There are many parameters; almost all the components of
simulation concept for predicting regenerative work piece machine tool and tool system are involved in the generation
vibration of five-axis milling process. of chatter vibration. In general, chatter vibrations occur due
Monitoring of machine condition plays a very important to lack of rigidity in the machine tool and cutting condition.
role in manufacturing high-quality and low-cost compo- Altering machine tool is not possible, but predicting the
nents. Development of such system requires reliable right cutting condition to reduce the chatter is possible by
machining data that reflect the machining process. Zhang controlling the process parameter of the end milling. In our
[13] proposed and demonstrated a tool condition monitor- study, the process parameters selected are helix angle of
ing in end milling based on the vibration signal collected cutting tool, spindle speed, feed rate, and axial and radial
through microcontroller-based data acquisition. Nakagawa depth of cut. The vibration amplitude is measured by using
[14] in his work proposed a new method of monitoring twin-channel FFT analyzer (COCO 80), and the accelera-
chatter vibration in end milling of hardened steels and tion amplitudes are picked at two locations, one in the feed
concluded that vibration frequencies differed during high direction on the work piece holder and the other in the axial
and low cutting speed conditions. Rahim [15] developed cutting direction in the spindle. The resulting vibration
vibration measuring unit using a microelectromechancial measurement in terms of displacement, velocity, and
system accelerometer, and experimental tests were carried acceleration amplitude collected in the form of time
out to characterize the device and the preliminary tests waveforms and frequency spectrum are shown in Figs. 1
proved that the developed measurement unit is capable of and 2, respectively.
sensing, measuring, and condition monitoring. Tansel [16] The time wave form is a time domain analysis which uses
estimated wear and tool breakage by using acoustic the history of the signal. The signal is stored in the analyzer,
emission signals. and any non-steady or transient impulses are noted. Discrete
Chatter vibrations can occur due to both regenerative damages due to built-up edge formation, resonance condition
and non-regenerative effects and depend upon many can be identified from the wave form. The acceleration
parameters such as the cutting speed, the feed rate, the waveform indicates that pulse occurs periodically with a
axial depth of cut, and the spindle speed [17]. During period of 2 s. The frequency spectrum is a plot of the
cutting, the measurement of vibration on spindle and tool is amplitude of the vibration response versus frequency and can
of great importance in both the development and monitor- be derived by using digital fast Fourier analysis of the
ing of high-speed milling [18]. Under a normal cutting waveform. The peak level is the indication of maximum
condition in the milling process, the dominant frequency vibration generated in the milling, and the maximum
components in the spectrum graph are around the tooth acceleration amplitude of the milling is noted for our study.
passing frequency [19]. In milling, the dominant frequency components in the
In this present work, the main objective is to develop a spectrum graph are around tooth passing frequency (ft) and
mathematical model to predict the vibration amplitude in their harmonics [20]. The tooth passing frequency (ft) can
terms of machining parameters such as helix angle of be calculated from the following equation
cutting tool, spindle speed, feed rate, and axial and radial
nX N
depth of cut. During milling, the vibration amplitude is Tooth passing frequencyðft Þ ¼ ðHzÞ ð1Þ
measured in both cutting and feed directions. The mathe- 60
matical model helps us to study the direct and interaction where N=spindle speed (rpm) and n=number of teeth of
effect of each parameter. end mill cutter.
The vibration resulted by the interaction of the tool and
work piece has characteristic frequency with the multiples of
2 Vibration analysis tooth passing frequency at 1×, 2×, 3×, etc. In Fig. 2, for the
given set of machining parameters, the dominant frequency
During milling, the cutter and work piece move with each occurs at the second multiples of tooth passing frequency,
other with a frequency determined by the natural frequency i.e., at 333.33 Hz. It is due to the fact that the second
of the machine tool. Chatter is a resonant vibration that multiples of tooth passing frequency coincide with the
occurs when forces acting on the cutting tool cause it to natural frequency of the machine tool resulted in resonance.
vibrate at a natural frequency of the machine in which a
minimum excitation produces maximum amplitude. Once
this condition is established, the interaction between the 3 Experimental design
cutter and work piece will sustain vibration, and constant
pounding will reduce tool life and impair surface finish, and In the present work, helix angle of cutting tool, spindle
also high amplitude may cause damage to machine tool. speed, feed rate, and axial and radial depth of cut have been
Int J Adv Manuf Technol (2011) 53:453–461 455
considered as the process parameters for cutting condition parameter variable. Box and Hunter [21] proposed central
monitoring, and the peak acceleration amplitude measured composite rotatable design for fitting a second-order
in the feed and axial cutting direction is taken as a response response surface based on the criterion of rotatability. The
variable (Table 1). selected design plan [21] chosen consists of 32 experiments
Response surface methodology is the most informative (Table 3). It is five factors—five levels central composite
method of analysis of the result of a factorial experiment. rotatable design consisting of 32 sets of coded conditions.
The response acceleration amplitude of the vibration A can The design for the above said experiment comprises of a 1/2
be expressed as a function of process parameters helix replication of 25 (=16) factorial design plus six center points
angle (α), spindle speed (N), feed rate (Z), and axial (X) and and ten star points. These correspond to first 16 rows, the
radial depth of cut (Y). last six rows, and rows from 17 to 26, respectively, in the
design plan shown.
Acceleration; A ¼ fðaiu ; Niu ; Ziu ; Xiu ; Yiu Þ þ eu ð2Þ
For 1/2 replicate, the extra point included to form a
where f=response surface, eu =residual, u=no of observa- central composite design, α becomes 2ðk1Þ=4 ¼ 2. The
tions in the factorial experiment, and iu represents level of upper limit of the parameter is coded as 2; lower limit, as
the ith factor in the uth observation. −2; and the coded values for intermediate values were
When the mathematical form of f is unknown, this calculated from the following relationship [22]:
function can be approximated satisfactorily within the
2ð2X ðXmax þ Xmin ÞÞ
experimental region by polynomials in terms of process Xi ¼ ð3Þ
ðXmax Xmin Þ
where,
Xi The required coded value of a variable X
X Is any value of the variable from Xmin to X max
Xmin Is the lower limit of the variable
Xmax Is the upper limit of the variable
4 Experimental setup
−2 −1 0 1 2
able machinable metal, which finds application in automo- where b0 =constant, bi =linear term coefficient, bii =quadratic
bile and valve industries. The dimension of the work piece term coefficient, and bij =interaction term coefficient.
specimen was 32 mm×32 mm in cross section and 40 mm The values of the coefficients of the polynomials were
in length. The vibration amplitude is measured by using calculated by multiple regression method. A statistical
twin-channel FFT analyzer (COCO 80), shown in Fig. 3. software QA Six Sigma DOEPC IV was used to
The acceleration amplitude is measured in the feed calculate the values of these coefficients. The second-
direction on the work piece holder (channel I) and in the order mathematical model was developed by neglecting
axial cutting direction in the spindle (channel II). The data the insignificant coefficients of the acceleration ampli-
are acquired in the FFT analyzers and are tabulated to tude measured in the feed direction and in the axial
obtain the mathematical model (Table 3). cutting direction.
For accelerometer—channel I—Vice
36:045 XY ð6Þ
Where
α helix angle in (°)
Z feed rate in mm/rev
Y radial depth of cut in mm
N cutting speed in rpm
X axial depth of cut in mm
Response Factors df Lack of fit—df Pure error F ratio R ratio Whether model is adequate
calculated R ratio of the model is above the standard value 6 Results and discussion
for a desired 95% level of confidence. It is evident from
Table 3 that the error between the experimental value and A mathematical model was developed to predict the
predicted value is less than 5%. acceleration amplitude in feed and axial cutting direction
Specimen no. Control factors Acceleration amplitude—(channel 1)×103mm/s2 Acceleration amplitude—(channel 2)×103mm/s2
α N Z X Y Observed value Predicted value % Error Observed value Predicted value % Error
6.1 Direct effect of variables takes the full load and the cutting forces increase rapidly.
The force continues to increase until the tooth leaves the cut
In this work, the effects of helix angle, spindle speed, feed and then suddenly drops. The shock load produced acts
rate, axial depth of cut, and radial depth of cut were with the drive mechanism of the machine to produce
experimentally investigated. From Figs. 4, 5, 6, 7, and 8, it chatter. The use of helical cutter instead of a straight one
is clear that the helix angle, feed rate, and axial depth of cut eliminates chatter vibration [23]. It is evident from Fig. 3
have a significant effect on acceleration amplitude in the that the acceleration amplitude gets decreased by increasing
feed direction and in the axial cutting direction. the helical angle of the cutting tool, and it is optimal at an
angle of 45°.
6.1.1 Direct effect of helix angle
6.1.2 Direct effect of spindle speed
Figure 4 shows that the increase in helix angle resulted in
reduced vibrations in both the channels measured along From Fig. 5, it is understandable that the spindle speed has
feed and axial cutting direction, and for helix angle 45°, the a significant effect on vibration when it is picked up in the
vibration is minimal in both cases. The cutting action of axial cutting direction and not significant in the feed
the tooth formed by a straight flute is intermittent. When the direction. The cutting forces acting on the tool are sustained
tooth enters the work piece, the whole length of the tooth by the spindle speed in the axial direction, and in the feed
direction, the force is sustained by the work piece fixture. It
is evident from the experiments that the vibration picked up
in the spindle (channel II) has a significant value for spindle
Fig. 8 Direct effect of radial depth of cut in axial cutting direction Fig. 10 Contour graph of interaction effect of helix angle×axial depth
(channel-II) of cut in feed direction (channel I)
460 Int J Adv Manuf Technol (2011) 53:453–461
6.1.5 Direct effect of radial depth of cut The interaction effects of helix angle and axial depth of
cut on acceleration amplitude in the feed direction
From Fig. 8, it is understandable that the radial depth of cut (Fig. 10) show that increase in helix angle resulted in
has a significant effect on vibration when it is picked up in decrease of acceleration amplitude with descending order
the axial cutting direction. By decreasing the width of cut, the for all the levels of axial depth of cut. The trends were
tendency of vibration can be reduced [20]. The tool deflection found to get slightly changed at helix angle of 45°, and
in the decreased width of cut is minimal, which will reduce for the last level, the acceleration amplitude increases
the tendency to chatter. It is concluded from Fig. 8 that the with the increase in helix angle for ascending order of all
acceleration amplitude reduced with decrease in depth of cut the levels of axial depth of cut. The increase in flute angle
and the vibration is minimal at radial depth of 2 mm. will reduce shock load and hence results in reduced
vibration.
6.2 Interaction effect of variables
6.2.3 Interaction effect of spindle speed and axial
A strong interaction was observed between various process depth of cut
parameters for vibration amplitude measured in both feed
direction and axial cutting direction. The most significant The interaction effects of spindle speed and axial depth of
interaction effect was found in the feed direction. The contour cut on acceleration amplitude in the feed direction (Fig. 11)
graph between the most significant process parameter indicate that for the first three levels of axial depth of cut,
interactions is shown in Figs. 9, 10, and 11. The following increase in spindle speed resulted in decrease of accelera-
conclusion can be made from these interaction plots. tion amplitude. The trend slightly gets reversed at the last
two levels of axial depth of the cut; increase in spindle
6.2.1 Interaction effect of feed rate and axial depth of cut speed resulted in increased vibration. The threshold for both
the parameters lies in the middle level, which gives a
The interaction effect of feed rate and axial depth of cut on minimum vibration when both parameters are considered at
acceleration amplitude in the feed direction shown in the a time.
Specimen no. Control factors Acceleration amplitude—(channel 1)×103mm/s2 Acceleration amplitude—(channel 2)×103mm/s2
α N Z X Y Observed value Predicted value % Error Observed value Predicted value % Error
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