Special Issue Article

Advances in Mechanical Engineering

2016, Vol. 8(7) 1–10
Ó The Author(s) 2016
Research on impacts of mechanical DOI: 10.1177/1687814016655778
aime.sagepub.com
vibrations on the production machine
to its rate of change of technical state

Štefánia Salokyová, Radoslav Krehel’, Martin Pollák and Marek Kočiško

Abstract
The article observes the amount of vibration on the bearing house of a turning lathe selected in advance through the
change of the revolutions per minute and the thickness of the removed material in frontal type of lathe processing.
Increase in mechanical vibration values depending on the value of nominal thickness of splinter was observed during
changing technological parameters of the drilling process as a consequence of rotation speed of the motor. The vibration
acceleration amplitude course changes depending on the frequencies are evaluated together for 400, 800 and 1200
motor r/min. A piezoelectric sensor of the type 4507B-004 from the Brüel & Kjaer Company was used for monitoring
the frequency analysis of the vibration, which was attached to the bearing house of the lathe TOS SV 18RB. The vibra-
tion signal measured during the processing and during the time period is transformed through the means of a quick
Fourier transformation to the frequency spectrum in the range of 3.0–10.0 kHz. Measured values of vibration accelera-
tion amplitude were processed and evaluated by the SignalExpress software.

Graphical abstract
Unwanted vibration in machine tools like lathe is one of the main problems as it affects the quality of the machined parts
and tool life and creates noise during machining operation. Bearings are of paramount importance to almost all forms of
rotating machinery and are the most common among machine elements. The article describes in more detail the issue
of vibrations created when machining the material by lathe turning. It also includes execution, experiment evaluation in
this field, and comparison of measured vibrations’ acceleration amplitude values according to the standards.

 

Keywords
Lathe processing, mechanical vibration, vibration acceleration amplitude, frequency, frequency spectrum

Date received: 16 December 2015; accepted: 30 May 2016
Academic Editor: José Tenreiro Machado
Introduction
Research on mechanical vibration and methods for its
elimination presently gained an importance. It relates
Department of Computer aid of Manufacturing Technologies, Faculty of
Manufacturing Technologies, Technical University of Košice, Prešov,
Slovakia
Corresponding author:
Radoslav Krehel’, Department of Computer aid of Manufacturing
Technologies, Faculty of Manufacturing Technologies, Technical University
of Košice, Prešov 08001, Slovakia.
Email: radoslav.krehel@tuke.sk

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open-access-at-sage).
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2 Advances in Mechanical Engineering
to the spread of speed machining methods. Till now,
the research on vibration issues during metal processing
through machining was not sufficient. The difference
and benefit of this article when compared to that of the
work done by Gerard and from Eze is examining the
effect of generating a vibration in the other working
and operational conditions set during operation. The
research will be focused on vibration measurements
with different objectives, namely, to establish the most
appropriate setting of operating parameters and opti-
mize the machining process, eliminating the influence
of vibrations. The expected result was obtained.1,2
Significant step forward was made in the research
on basic and specific principles of vibration during
metal machining. Vibration is an undesired effect dur-
ing machining; therefore, this issue has to be addressed
more frequently.3–5
The diagnostic evaluation methods are mainly based
on objective and quality of data about the observed
system, which we collect through either one-time mea-
surement or long-term observation as is documented in
the book by Helebrant and Ziegler6 and Altıntasx et al.7
Early determination of emerging defect has a big effect
on the fluency and efficiency of production, on evalua-
tion of the machine state, symptoms of machine dam-
age, identification of damage, or life cycle prognosis. In
our case, one of the three characteristic parameters will
be used for the diagnosis in the field of mechanical
vibration, namely, vibration acceleration. The goal of
this article is to address the possibility of vibration dur-
ing frontal drilling as a consequence of changing depth
of removed material.
The practical significance of the research is the fact
that an overview of the individual resources and the
distribution of the sensor element interaction can be
obtained using the set of measurements. From these
measurements, it is possible to create a systematic con-
cept for obtaining measurements of the intersection of
elementary indicators, in the form of a frequency spec-
trum of signal with clearly distributed amplitude and
frequency. Each measurement includes components
generated by mutual interference, so only the intersec-
tion of several measurements can show useful vibro-
diagnostic real signal. The measurement is only one
elemental component of the whole concept of measure-
ments, because it focuses only on one type of vibration
sources and changes in those resources are production
machining parameters.
Monitored indicators are vibration. The essence of
diagnostics is to monitor the degree of deformation of
the original signal on the output signal. Representative
of diagnostic signals is the oscillations of the constitu-
ent parts whose intensity is determined by the intensity
of shocks in elementary connections, such as bearings
and thus the technical condition of these structural ele-
ments. The natural frequency of diagnostic signals is
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generated by a given weight and stiffness parameters of
the various parts of the machinery.8,9
Measuring objects are individual parts of a lathe,
which is believed to be the greatest effect of vibration,
as they are situated close to the major parts of the
rotary lathe. It is measured on the surface of a lathe
using piezoelectric sensors and the gradual stoking of
the sensors at various points of their fixing. Gradually,
it makes changes to the process parameters and when
any change is made, the measured data are saved in the
database. The technique of data processing is provided
by a special computer program that translates the mea-
sured electrical data into a numeric format of velocity
and vibration acceleration. These are subsequently pro-
cessed into a plot. Interpretation of results is processed
as one of the elementary measurements for a particular
production machine and the results allow recommenda-
tion on production tasks; especially mass production,
appropriate and optimal working conditions bring the
production with the lowest machine wear and prolong
its life and functionality. At the same time, the mea-
surement is one part of the whole complex in which it
will be possible to form an appropriate mathematical
statistics’ intersection of elementary indicators, in the
form of a frequency spectrum of signal, which is clearly
distributed in amplitude and frequency. The company
benefits are less cost, and production benefits are less
losses, increased machine life, and higher quality
production.10
Analysis of current state
During material processing through machining, com-
plex vibration processes occur. They occur in the system
machine-tool-processed material. Sometimes, the vibra-
tion is so small that it does not have any negative effect.
However, there are also cases when the vibration is very
intense during machining. From the physical nature
point of view, various types of vibration can occur in
the system, stated as per Sidhpura 2012—own vibra-
tion, forced vibration, and a self-occurring vibration.11–
13
Forced and self-occurring vibrations are undesired
effect during the processing, excluding some specific
cases such as processing through forced vibration knife,
during which a better creation of splinter occurs, and
reduced intensity of cutting edge wear of the tool as is
documented by Mádl.14
During the processing and also when there is no visi-
ble vibration, the cutting force fluctuates continuously.
Immediate size of the cutting force ranges around the
median. Especially the fluctuation is caused mainly by
the unbalanced attributes of the processed material,
irregularities of the processed surface, which is docu-
mented in the book by Mádl.14 To demonstrate this,
Figure 1(a) depicts the simplified model of the
Salokyová et al. 3

Table 1. Measured values of the experiments.

Constant parameters Changing parameters Output

Type of material Reduction in the Motor speed (r/min)
material (mm)

Experiment 1 STN 11 503 0 400, 800, and 1200 Vibration on the

Experiment 2 0.5 bearing housings
Experiment 3 1
Experiment 4 2

processing system, which characterizes the state during

orthogonal processing during machining.15–17
Physical point A in point of interaction of the pro-
cessed material and the tool vibrates due to changing
forces Fc and Fcn in the direction of the z-axis and in
direction of the y-axis with certain frequencies and
amplitudes. Vibration of individual elements of the
processing system can also cause the increase in tool
wear, destruction of the tool, increase in processing
noise, or malfunction of the processing machine.18,19
For the purposes of experiments and evaluation of
measured values of vibration acceleration, basic the-
ories (vibration and oscillation theory, systems theory,
measurement theory, experiments, and probability the-
ory) and basic methods (vibration diagnosis method,
methods of measurement waveforms and amplitudes,
methods for frequency spectrum generation, and math-
ematical statistics methods) were used.20–22

Figure 1. Model of the processing system during machining: (a)

Experimental conditions
The experiments were performed in the laboratory of
splint processing on alloy type construction steel of the
type STN 11 503 class 11. There have been 12 consecu-
tive measurements in four experiments. Input constant
and changing technology and material parameters,
under which the experiments have been carried out, are
listed in Table 1. Figure 1(b) depicts the material steel
type STN 11 503 class 11 before and after processing.
Description of the technical system during
the measurement and evaluation of the
vibration
A piezoelectric sensor of the type 4507B-004 from the
Brüel & Kjaer Company was used for monitoring the
frequency analysis of the vibration, which was attached
to the bearing house of the lathe TOS SV 18RB through
magic glue (Figure 2).
The piezoelectric sensor of the vibrations monitors
the vibrations during the processing in the direction of
the lathe processing axis. The data collector records the
acceleration of the vibration signal and integrates it
with the speed of the vibration signal.23 Acceleration as
material before processing and (b) material after processing.
a physical quantity at most corresponds to the size of
vibration, and it is given only acceleration. The vibra-
tion sensor measures the speed value, which subse-
quently transforms into acceleration by converter using
mathematical operation of integration.24–26
Vibration acceleration amplitudes recorded in the
axis of the lathe processing in this way are written into
the memory of the Compact DAQNI 9233 device of
the National Instruments Company and are evaluated
in the frequency spectrum through a means of a quick
Fourier transformation. This allows determining the
quantity of the harmonic frequencies in the monitored
signal. The evaluated signal can then be immediately
observed on a portable computer, thanks to the
SignalExpress software. The SignalExpress program
contains several functions necessary for the proper eva-
luation, recording, and analysis of the measurements.23
Measured values of the experiments
The vibration signal measured during the processing
and during the time period is transformed through a

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4 Advances in Mechanical Engineering

Figure 2. Attachment of the vibrations sensor on the bearing house of the lathe.

Figure 3. Graphical dependency of the vibration acceleration amplitude on the frequency with material removal of 2.0 mm.

means of a quick Fourier transformation to the fre-
quency spectrum in the range of 3.0–10.0 kHz. The gra-
phic dependencies of the vibration acceleration
amplitude course changes depending on the frequencies
are evaluated together for 400, 800, and 1200 motor r/
min (these rotation speeds were selected as working
parameters, because only these speeds can be adjusted
by discrete changing of machine transfer). The vibra-
tion acceleration amplitude course changes for frequen-
cies of 400, 800, and 1200 motor r/min and material
removal of 2.0 mm are graphically displayed as an
example in Figure 3. Graphical dependencies of the
vibration acceleration amplitude and vibration frequen-
cies for 400, 800, and 1200 r/min without load and with
material removal of 0.5 and 1.0 mm have also been
analogously displayed.
Based on graphical representations of vibration
acceleration amplitudes, vibration frequency spectrum
covers on the housing have been created and based on
the comparison graph, frequency spectrum covers for
the common set of experiments have been created.
Figure 4(a) depicts the comparison graph of frequency
spectrum covers combined for the selected set of spin-
dle rotation speeds of 400, 800, and 1200 r/min without

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Salokyová et al. 5

Figure 4. (a) Comparison chart of frequency spectrum covers without load for 400, 800, and 1200 r/min of the motor; (b)
comparison graph of frequency spectrum covers at removed thickness 0.5 mm and motor speeds of 400, 800, and 1200 r/min; (c)
comparison graph of frequency spectrum covers at removed thickness 1.0 mm and motor speeds of 400, 800, and 1200 r/min; and
(d) comparison graph of frequency spectrum covers at removed thickness 2.0 mm and motor speeds of 400, 800, and 1200 r/min.

a load. Comparison graph of frequency spectrum cov-
ers for motor rotation speeds 400, 800, and 1200 r/min
with material removal of 0.5 mm is depicted in Figure
4(b), with material removal of 1.0 mm in Figure 4(c)
and with material removal of 2.0 mm in Figure 4(d).
Under three researched motor speeds of 400, 800,
and 1200 r/min without material removal, the increased
vibration values of researched range 3.0–10.0 kHz are
found in two frequency spectrums, specifically 4.0
through 4.3 kHz and 7.0 through 9.0 kHz (Figure 4(a)).
Size of the vibration acceleration amplitude without
load in comparison range reaches high value of
3.64.1024 g at frequency 4.2 kHz and motor speed of
1200 r/min. With the increasing numerical value of

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6 Advances in Mechanical Engineering

motor speed without load, in researched range, the
value of vibration acceleration amplitude increases reg-
ularly and in comparison for speeds 400 and 1200 r/
min, vibration acceleration amplitude value increases
as much as 98.53%.
Based on examination of the vibration acceleration
amplitude and the corresponding frequencies at
researched motor speeds of 400, 800, and 1200 r/min
with material removal of 0.5 mm (Figure 4(b)), it can
be said that during the processing one frequency range
of higher vibrations was found, namely, in the fre-
quency spectrum 3.0–4.0 kHz for the overall researched
frequency spectrum 3.0 through 10.0 kHz. Maximum
vibration acceleration amplitude value reached
1.38 3 1024 g at the frequency 3.3 kHz and motor
speed of 800 r/min. With increased numeric value of
motor speed at material removal 0.5 mm in researched
field, the vibration acceleration amplitude value
increases at the beginning and then drops significantly
when compared to the motor speeds of 400 and 800 r/
min, where the vibration acceleration amplitude value
increases as much 99%.
We can see from the vibration acceleration ampli-
tude and the corresponding frequencies for researched
motor speeds and thickness of removed material of
1.0 mm (Figure 4(c)) that the more significant values of
vibration acceleration amplitude were reached in two
areas, namely, in frequency range of 3.0–5.3 kHz and
9.0–10.0 kHz. Size of the vibration acceleration ampli-
tude in the comparison range reaches the maximum
value of 5.76 3 1025 g at frequency of 3.5 kHz and
motor speed of 1200 r/min. With increasing numerical
value of motor speed in the researched range, the
vibration acceleration amplitude increases constantly
and when compared to motor speeds 400 and 1200 r/
min, the vibration acceleration amplitude value
increases as much as 94.8%.
We can state based on the vibration acceleration
amplitude graphical relation and frequency (Figure
4(d)) that for material removal of 2.0 mm and motor
speeds of 400, 800, and 1200 r/min, two areas of
increased vibrations have occurred (3.0–5.2 and 9.3–
10.0 kHz). With the increasing numerical value of
motor speed in the researched range, the vibration
acceleration amplitude value increases constantly and
when compared for motor speeds 400 and 1200 r/min,
vibration acceleration amplitude value increases as
much as 96.7%.
Chart of maximum vibration acceleration amplitude
values is created from the comparison graphs of fre-
quency spectrum covers (Table 2).
Criteria for determining the rate of deterioration of
the technical condition of the machine were the change
in accuracy of machining, resizing removal of electric-
ity, and change in the generated noise levels. These
three criteria are directly linked statistically with the
deterioration of the technical condition of machines. In
the evaluation of those criteria for the relevant vibra-
tion levels, it can be concluded that the technical condi-
tion is getting worse almost proportionally with
increasing magnitude of the vibration.
Experimental results consist also of the evaluation of
comparison graphs of frequency spectrum covers in the
structure independently of two researched motor speeds
and together for the material removal. Comparison
graph of vibration acceleration amplitude covers and

Table 2. Maximum values of the vibration acceleration amplitude.

Maximum values of the vibration acceleration amplitudes (g), noise (dB), electric energy consumption (kW h), machining accuracy
(mm)
Experiments Motor speed Acceleration Deviation of noise Deviation of electric energyb Deviation of machining
(r/min) value (g) than the normala (%) consumption than accuracyc than the
the normala (%) normala (%)

Experiment 1 400 5.34 3 1026 0.53 0.99 2.79

800 7.05 3 1025 4.20 7.16 16.10
1200 3.64 3 1024 29.53 21.28 34.31
Experiment 2 400 1.39 3 1026 0.14 0.32 1.19
800 1.38 3 1024 14.32 14.61 21.44
1200 3.49 3 1025 2.16 3.58 9.65
Experiment 3 400 3.02 3 1026 0.32 0.56 1.98
800 4.29 3 1025 2.89 4.11 10.77
1200 5.76 3 1025 3.51 5.79 11.58
Experiment 4 400 3.36 3 1026 0.41 0.63 2.15
800 3.78 3 1025 2.52 3.84 9.94
1200 1.03 3 1024 11.04 13.76 19.78
a
Normal: value at 1.15 3 1026 g (selecting a low vibration value).
b
Energy absorbed by the vibrations.
c
Mechanical vibration reduces the accuracy of machining.

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Salokyová et al. 7

Figure 5. (a) Comparison graph of frequency spectrum covers without load and material removal of 0.5, 1.0, and 2.0 mm at motor
speed of 400 r/min; (b) comparison graph of frequency spectrum covers with material removal 1.0 and 2.0 mm at motor speed of
800 r/min and (c) comparison graph of frequency spectrum covers with material removal 1.0 and 2.0 mm at motor speed of
1200 r/min.

frequency spectrums of bearing vibrations at motor
speed 400 r/min and material removal of 0.5, 1.0 and
2.0 mm is depicted in Figure 5(a). Figure 5(b) depicts
the comparison graph at motor speed 800 r/min and
Figure 5(c) depicts the comparison graph at motor
speed of 1200 r/min.
We can see from the comparison graph of frequency
spectrum covers (Figure 5(a)) for processing of material
selected in advance and set motor speed of 400 r/min
that the highest vibration resonance values were
achieved for processing without load. For processing
with material removal, the vibration acceleration
amplitude values are approximately the same. At the
same time, we can state that with the increasing mate-
rial removal, the vibration values increase constantly.
When compared with material removal of 2.0 mm, it is
2.4 times more (increasing the maximum value of the
material removal rate of 2 and 0.5 mm), which repre-
sents the value of 58.63 %.
Based on graphical representation (Figure 5(b)), it
can be said that for processing at motor speed of 800 r/
min, the highest resonance values were reached for pro-
cessing with material removal of 0.5 mm. With the
increasing value of material removal, the vibration
acceleration amplitude values drop significantly. The
difference between material removal of 0.5 and 2.0 mm
represents the value of 72.6% which is 3.6 times less.
Stated comparison graph (Figure 5(c)) indicates that
the course of the vibration acceleration amplitude for
all measurements is similar in shape. However, we
observe a change of resonance vibration values where
the highest measured values are observed for process-
ing without a load and material removal of 2.0 mm.
The difference between the maximum and minimum

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8 Advances in Mechanical Engineering

Figure 6. (a) Resonance vibration characteristic based on motor speed for processing without load and material removal of 0.5 mm
and (b) resonance vibration characteristic based on motor speed and material removal of 1.0 and 2.0 mm.

value of vibration acceleration amplitude is represented
by the value of 94.3%, which is 10 times more.
Based on measured vibration acceleration amplitude
values, we can deduce a characteristic of resonance
vibrations dependent on motor speeds, which is
depicted in Figure 6(a) for processing without load and
material removal of 0.5 mm and Figure 6(b) for mate-
rial removal of 1.0 and 2.0 mm.
Based on this, using correlation and regression anal-
ysis, we can determine dependence between motor
speeds and vibration resonance values. Units are
mutually statistically correlated. Regression analysis is
used for the determination of type and constants of
functions, which determines the method of smallest
squares on the basis of empirically determined data.
Linear regression with several unknown parameters is
used for evaluation of quantitative relations. We
achieve the smallest squares method through the mean
values, where the sum of squared distances of originally
measured resonance values from the regression line is
the smallest possible. Determination coefficient repre-
sents the proportion of mutual dispersion, which is
what percentage wills the change of one variable affect
the other one.
Based on maximum vibration acceleration ampli-
tude values and motor speeds, relations between these
two have been discovered. Regression equations have
been created and determination coefficients are calcu-
lated, which are listed in individual graphic relations
(Figure 6(a) and (b)). The determination coefficient is
high for processing without material and material
removal of 1.0 and 2.0 mm when compared to the value
of determination coefficient for material removal of
0.5 mm. The coefficient indicates the reliability value.
For example, for processing with material removal of
2.0 mm, 93.38% increase in vibration resonance value
is dependent on the increase in lathe motor speed.
Proposal and application of knowledge
Based on performed and evaluated experiments, it is
recommended, from the researched set of motor speeds,
to use the processing of material selected in advance
motor speed of 400 r/min when compared to motor
speeds of 800 and 1200 r/min, which reduces wear of
the lathe housing and at the same time increases its life
span, reduces time of failure downtimes, and increases
the economic efficiency of the operation. The measure
is a useful contribution to the machining using the set-
ting operating parameters for which the measurement
was carried out at the workplace and for a specific type
of machine. The effect of using the acquired knowledge
is widely used in many general piece production and
long-term serial production, where there is no need to
change the operating parameters of production.
Conclusion
Objective research focused on monitoring the vibration
values arising during operation, which is indicated

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Salokyová et al.
when using the operating parameters. Based on norm
ISO 10816-3, the lathe TOS SV 18RB with 9 kW output
belongs to group 4, where individual parts and sub-
groups of machines integrated into the overall system
working in normal operational conditions belong (elec-
tric machines up to 15 kW). The focus was fixed on
obtaining information on the speed of deterioration of
the technical state of the machine in terms of vibrations
arising in particular depending on the size of the
mechanical vibration. Criteria for determining the rate
of deterioration of the technical condition of the
machine were the change in precision machining, resiz-
ing removal of electricity, and change in the generated
noise levels. These three criteria are directly linked sta-
tistically with the deterioration of the technical condi-
tion of machines. In assessing of the following criteria
for the relevant vibration values, it can be concluded
that the technical condition deteriorates almost in direct
proportion to the increasing size of vibration. Based on
the resonance vibration value of the machine, we can
state that the long-term processing under given condi-
tions on our lathe does not cause such resonance, which
would reduce the life span since the maximum vibration
acceleration amplitude value we have recorded was
3.64 3 1024 g. Prescribed critical vibration value for
this group of machines as per norm stated above has
the value of 4.5 mg. With the increasing thickness of
material removal, there was a decrease in the amplitude
of vibration acceleration. From the perspective of opti-
mizing the process of turning on the lathe TOS SV
18RB, it can be stated that it is necessary to avoid the
revolutions of 800 and 1200 r/min during machining
without load, considering the value of mechanical
vibration. Above-mentioned achievements form a part
of experiments, comparing the input parameters and
their suitability for use under the conditions of turning.
Compliance with ethics requirements
This article does not contain any studies with human or ani-
mal subjects.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Funding
The author(s) disclosed receipt of the following financial sup-
port for the research, authorship and/or publication of this
article: The research work was supported by the Project of
the SF of the EU, Operational Programme Research and
Development, Measure 2.2 Transfer of knowledge and tech-
nology from research and development into practice, project:
Research and development of intelligent nonconventional
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9
actuators based on artificial muscles. ITMS project code:
26220220103, projects VEGA 1/0409/13 and KEGA 027
TUKE—4/2014, ITMS project code: 26220220125;
Operational Programme Research and Development support
research activities in Slovakia.
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