Optimization of cutting tool geometry and machining parameters in turning process

• Published in: Materials today : proceedings 2021-01, Vol.38, p.3351-3357
• Main Authors: Saravanamurugan, S., Shyam Sundar, B., Sibi Pranav, R., Shanmugasundaram, A.
• Format: Article
• Language: English
• Subjects: ANOVA; Finite Element Analysis; Regenerative Chatter; Response Surface Methodology; Vibration control
• ISSN: 2214-7853; 2214-7853
• DOI: 10.1016/j.matpr.2020.10.246

Vibrations play a major role in increasing the cost of production as they lead to a poor surface finish of the machined product and can also damage the cutting and machine tool. In this work, the influence of cutting tool geometry of a turning tool and machining parameters used in turning operations on regenerative chatter vibration during orthogonal cutting was studied. The optimum values of orthogonal rake angle, clearance angle, cutting tool overhang, feed rate and depth of cut are found by developing a model using design of experiments and the model was analysed using a statistical technique known as response surface method (RSM). The objective is to optimize cutting tool geometry and machining parameters of turning process by minimizing the real part of frequency response function (FRF) which is a response of a cutting tool subjected to a harmonic force. The harmonic analysis, carried out using software ANSYS, was used to get the peak value of real part of frequency response function (RFRF) of the cutting tool and its magnitude has to be minimized to improve the machining stability against regenerative chatter during machining. It may be inferred from the results that the tool rake angle, clearance angle, overhang of the cutting tool, feed rate and depth of cut are interacting with each other and influence the machining stability simultaneously. Hence, it may be advisable to pick an optimum set of machining parameters for the specific combination of cutting tool geometry to have vibration-free machining.