Abstract
This paper reports on the effects of spindle attributed forced vibrations on machinability characteristics of vertical milling process. The effects of three levels of spindle attributed forced vibrations along with feed rate and axial depth of cut are evaluated on surface roughness, dimensional accuracy, and tool wear under constant conditions of radial depth of cut and cutting speed. AISI P20 and solid carbide cutter are used as workpiece material and tool, respectively. Taguchi L9 standard orthogonal array is used for experiments followed by analysis of variance (ANOVA) for identifying significant parameters that affect surface roughness and dimensional accuracy. Tool wear in terms of crater wear (Kt) and tool flank wear (VBmax) is measured along with an analysis of chip** and built-up edges for accessing the influence of forced vibrations. It is found that machine tool vibration amplitude and axial depth of cut are statistically significant at 95 % confidence level for surface roughness, with vibration amplitude being the most contributing factor (83.4 %) followed by axial depth of cut (12.39 %). The dimensional accuracy is found to be insensitive to the parameters at stated confidence level. Higher values of vibration amplitude and feed rate are found to be resulting into excessive tool wear with vibration amplitude of 0.185929 mm/min combined along with a feed rate of 600 mm/min and an axial depth of cut of 0.15 mm resulting in catastrophic tool failure.
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This paper reports on the machinability characteristics of vertical milling process while incorporating one of the dynamic aspects of machine tools namely, “spindle forced vibrations.” This reportage provides a more comprehensive insight on the effects of dynamic aspects on the output parameters which are otherwise reported incorporating “chatter” only, which is a partial representation of whole dynamic paradigm.
The novelty in the work stems from the idea itself, wherein both magnitude of weight and spindle speed are varied over wide ranges to systematically investigate and quantify the effects of vibration amplitude levels on machining traits. The nature of work requires a further novelty in terms of methodology wherein a purpose built gripper for generating forced vibration is employed for the purpose.
The work finds its application in industry concerned with manufacturing of dies and mold. An underlying objective of the work is to assess how certain machining traits could be affected by service years (represented herein by vibrations attributed to spindle). Service years can be associated with vibration levels, and accordingly, their effects on stated performance measures can be incorporated for more realistic analysis on shop floor.
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Zahoor, S., Mufti, N.A., Saleem, M.Q. et al. Effect of machine tool’s spindle forced vibrations on surface roughness, dimensional accuracy, and tool wear in vertical milling of AISI P20. Int J Adv Manuf Technol 89, 3671–3679 (2017). https://doi.org/10.1007/s00170-016-9346-1
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DOI: https://doi.org/10.1007/s00170-016-9346-1