Tool and work piece vibrations measurement - a review
Article Sidebar
Main Article Content
Abstract
Tool condition monitoring is one of the important aspects in machining process to improve tool life. It comprises three important steps namely machining data acquisition, data analysis and decision making. Vibration in metal cutting has direct impact on the tool life as well as surface roughness. The present study focused on measurement of vibration during the machining process. Data acquisition is made by using various types of sensors. A wide variety of technologies like contact and non contact sensors have been used for real time data acquisition of tool or work piece vibrations. Research works carried out by many authors is highlighted in measurement of cutting tool and machine tool vibrations using different sensors. Influence of various input parameters like tool geometry, feed, speed and depth of cut on the magnitude of vibrations is discussed. Influence of vibration on surface roughness, tool life and power consumption is reviewed. Three dimensional vibration measurement with single Laser Doppler Vibrometer is also covered for precise analysis of vibration.
Downloads
Article Details
1. Proposal of Policy for Free Access Periodics
Authors whom publish in this magazine should agree to the following terms:
a. Authors should keep the copyrights and grant to the magazine the right of the first publication, with the work simultaneously permitted under the Creative Commons Attribution-NonCommercial-ShareAlike 4.0 that allows the sharing of the work with recognition of the authorship of the work and initial publication in this magazine.
b. Authors should have authorization for assuming additional contracts separately, for non-exclusive distribution of the version of the work published in this magazine (e.g.: to publish in an institutional repository or as book chapter), with recognition of authorship and initial publication in this magazine.
c. Authors should have permission and should be stimulated to publish and to distribute its work online (e.g.: in institutional repositories or its personal page) to any point before or during the publishing process, since this can generate productive alterations, as well as increasing the impact and the citation of the published work (See The Effect of Free Access).
Proposal of Policy for Periodic that offer Postponed Free Access
Authors whom publish in this magazine should agree to the following terms:
a. Authors should keep the copyrights and grant to the magazine the right of the first publication, with the work simultaneously permitted under the Creative Commons Attribution-NonCommercial-ShareAlike 4.0 [SPECIFY TIME HERE] after the publication, allowing the sharing of the work with recognition of the authorship of the work and initial publication in this magazine.
b. Authors should have authorization for assuming additional contracts separately, for non-exclusive distribution of the version of the work published in this magazine (e.g.: to publish in institutional repository or as book chapter), with recognition of authorship and initial publication in this magazine.
c. Authors should have permission and should be stimulated to publish and to distribute its work online (e.g.: in institutional repositories or its personal page) to any point before or during the publishing process, since this can generate productive alterations, as well as increasing the impact and the citation of the published work (See The Effect of Free Access).
d. They allow some kind of open dissemination. Authors can disseminate their articles in open access, but with specific conditions imposed by the editor that are related to:
Version of the article that can be deposited in the repository:
Pre-print: before being reviewed by pairs.
Post-print: once reviewed by pairs, which can be:
The version of the author that has been accepted for publication.
The editor's version, that is, the article published in the magazine.
At which point the article can be made accessible in an open manner: before it is published in the magazine, immediately afterwards or if a period of seizure is required, which can range from six months to several years.
Where to leave open: on the author's personal web page, only departmental websites, the repository of the institution, the file of the research funding agency, among others.
References
ABDUL, B. S.; SHIVAKUMAR, R. (1987) Detection of tool flank wear using acoustic signature analysis. Wear, v. 115, n. 3, p. 265-272.
AKESSON, H.; SMIRNOVA, T.; CLAESSON, I.; HAKANSSON, L. (2007) On the Development of a Simple and Robust Active Control System for Boring Bar Vibration in Industry. International Journal of Acoustics and Vibration, v. 12 , n. 4, p. 139-152.
ALONSO, F. J.; SALGADO, D.R. (2008) Analysis of the structure of vibration signals for tool wear detection. Mechanical Systems and Signal Processing. v. 22, n. 3, p. 735-748.
ANDREN, L.; HAKANSSON, L.; BRANDT, A.; CLAESSON, I. (2004) Identification of dynamic properties of boring bar vibrations in a continuous boring operation. Mechanical Systems and Signal Processing, v. 18, n. 4, p. 869–901.
BALAJI, M.; VENKATARAO, K.; MOHANARAO, N.; MURTHY, B. S. N. (2018) Optimization of drilling parameters for drilling of TI-6Al-4V based on surface roughness, flank wear and drill vibration. Measurement, v. 114, p. 332-339.
BELL, J. R.; ROTHBERG, S. J. (2000) Rotational vibration measurements using laser Doppler vibrometry: comprehensive theory and practical application. Journal of Sound and Vibration, v. 238, n. 4, p. 673-690.
CASTELLINI, P.; SCALISE, L.; REVEL, G. M. (2000) Vibration measurements for diagnosis of structural defects on human teeth. Measurement, v. 27, n. 1, p. 29-42
CHANG, F. Y.; RICHARD, J. H. (1989) Acoustic emission true RMS signals used to indicate wear of a high speed ceramic insert. Journal of Mechanical Working Technology. v. 20, p. 79-91.
CHANG, F. X. (2001) An Experimental Study of the Impact of Turning Parameters on Surface Roughness. Proceedings of the Industrial Engineering Research Conference. Paper n. 2036, GA.
CHELLADURAI, H.; JAIN, V. K.; VYAS, N. S. (2008) Development of a cutting tool condition monitoring system for high speed turning operation by vibration and strain analysis. International Journal of Advanced Manufacturing Technology, v. 37, p. 471–485.
CHERAN, G. L.; JIA-MING, L. (2007) Study on boring and drilling with vibration cutting. International Journal of Machine Tools and Manufacture, v. 47, n. 1, p. 133-140.
CHIH-CHERNG, CH.; NUN-MING, L.; KO-TA, CH.; HUA-LUN, CH. (2012) Experimental investigation of tool vibration and surface roughness in the precision end-milling process using the singular spectrum analysis. International Journal of Advanced Manufacturing Technology, v. 63, p. 797–815.
DAVID, A. S.; JOHN, S. A. ( 2006) Metal cutting theory and practice. Taylor and Francis, 1st edition, p. 45-69.
DAVID, E. O.; MATTHIAS, S. (2009) Automated robot-based 3D vibration measurement system. Sound & Vibration, v. 43, n. 4, p. 12-15.
DIMLA, D. E. SR.; LISTER, P. M. (2000) On-line metal cutting tool condition monitoring.: I: force and vibration analyses. International Journal of Machine Tools and Manufacture, v. 40, n. 5, p. 739-768.
DONGKYU, K.; KYIHWAN, P. (2013) Development of the pseudo 3-dimensional laser scanning vibrometer. 20th International Congress on Sound and Vibration (ICSV20), Bangkok, Thailand.
DONGKYU, K.; HAJUN, S.; HOSSAM, K.; JONGSUH, L.; SEMYUNG, W.; KYIHWAN, P. (2014) 3-D Vibration Measurement Using a Single Laser Scanning Vibrometer by Moving to Three Different Locations. IEEE transactions on instrumentation and measurement, v. 63, n. 8, p. 2028-2033.
DORNFELD, D. A.; KANNATEY, A. E. (1980) Acoustic emission during orthogonal metal cutting. International Journal of Mechanical Sciences. V. 22, p. 285-296.
EWINS, D. J. (1984) Modal Testing: Theory and Practice. Research Studies Press- John Wiley.
GHANI, A. K.; CHOUDHURY, I. A.; HUSNI. (2002) Study of tool life, surface roughness and vibration in machining nodular cast iron with ceramic tool. Journal of Materials Processing Technology. v. 127, n. 1, p. 17-25.
INMAN, D. J. (2001) Engineering Vibration. Prentice-Hall, 2nd edition, p. 258-269.
KOUROSH, T.; PER, G. (2008) Measurement of milling tool vibrations during cutting using laser vibrometry. International Journal of Machine Tools and Manufacture, v. 48, n. 3-4, p. 380-387.
LUKE, H. H.; JOSEPH, C. C. (2001) A Multiple Regression Model to Predict In-Process Surface Roughness in Turning Operation Via Accelerometer. Journal of Industrial Technology, v. 17, n. 2, p. 2-7.
MIGUÉLEZ, M. H.; RUBIO, L.; LOYA, J. A.; FERNÁNDEZ, S. J. (2010) Improvement of chatter stability in boring operations with passive vibration absorbers. International Journal of Mechanical Sciences, v. 52, n. 10, p. 1376-1384.
NGOI, B. K. A.; VENKATAKRISHNAN, K. (2000) An Acousto-Optic Vibrometer for Measurement of Vibration in Ultra-Precision Machine Tools. The International Journal of Advanced Manufacturing Technology, v. 16, n. 11, p. 830-834.
OSTASEVICIUS, V.; GAIDYS, R.; RIMKEVICIENE, J.; DAUKSEVICIUS, R. (2010) An approach based on tool mode control for surface roughness reduction in high-frequency vibration cutting. Journal of Sound and Vibration, v. 329, n. 23, p. 4866-4879.
PRASAD, B. S.; SARCAR, M. M. M.; SATISH, B. B. (2010) Development of a system for monitoring tool condition using acousto-optic emission signal in face turning—an experimental approach. International Journal of Advanced Manufacturing Technology. v. 51, p. 57–67.
RAHIM, I. A.; MISKAM, M. A.; SIDEK, O.; ZAHARUDIN, S. A.; MOHD, S. K. K. (2009) Development of a vibration measuring unit using a microelectromechanical system accelerometer for machine condition monitoring. European Journal of Scientific Research, v. 35, n. 1, p. 150–158.
ROBERTO, M.; LUCIANO, P.; GIANLUCA, R. (2000) Vibration measurements of tools inside fluids by laser Doppler techniques: uncertainty analysis. Measurement., v. 27, n. 2, p. 111–120.
ROBERTO, T.; MICHELETTI, G. F. (1989) Tool Wear Monitoring Through Acoustic Emission. CIRP Annals - Manufacturing Technology. v. 38, n. 1, p. 99-102.
SADETTIN, O.; ALI, O.; NECIP, C.; ERSAN, A. (2007) Tool wear evaluation by vibration analysis during end milling of AISI D3 cold work tool steel with 35 HRC hardness. NDT & E International, v. 40, n. 2, p. 121-126.
SALGADO, D. R.; ALONSO, F. J.; CAMBERO, I.; MARCELO, A. (2009) In-process surface roughness prediction system using cutting vibrations in turning. International Journal of Advanced Manufacturing Technology. v. 43, p. 40–51.
SIVASAKTHIVEL, P. S.;VELMURUGAN, V.; SUDHAKARAN, R. (2011) Prediction of vibration amplitude from machining parameters by response surface methodology in end milling. International Journal of Advanced Manufacturing Technology, v. 53, p. 453–461.
THOMAS, M.; BEAUCHAMP, Y. (2003) Statistical investigation of modal parameters of cutting tools in dry turning. International Journal of Machine Tools and Manufacture, v. 43, n. 11, p. 1093-1106.
TOBIAS, S. A. (1965) Machine-Tool Vibration. Blackie and Sons Ltd, Scotland. p. 132-135.
VENKATARAO, K.; MURTHY, P. B. G. S. N. ( 2016) Modeling and optimization of tool vibration and surface roughness in boring of steel using RSM, ANN and SVM. Journal of Intelligent Manufacturing, DOI: 10.1007/s10845-016-1197-y.
VENKATARAO, K. (2014) Tool condition monitoring by analyzing surface roughness, workpiece vibration and volume of metal removed in boring of steel. Thesis (Ph D in Machine design and Manufacturing). JNTUK: Kakinada.
VENKATARAO, K.; MURTHY, B. S. N.; MOHANRAO, N. (2013) Cutting tool condition monitoring by analyzing surface roughness, work piece vibration and volume of metal removed for AISI 1040 steel in boring. Measurement, v. 46, p. 4075–4084.
VENKATARAO, K.; MURTHY, B. S. N.; MOHANRAO, N. (2014) Prediction of cutting tool wear, surface roughness and vibration of work piece in boring of AISI 316 steel with artificial neural Network. Measurement, v. 51, p. 63–70.
WANG, H.; TO, S.; CHAN, C. Y.; (2013) Investigation on the influence of tool-tip vibration on surface roughness and its representative measurement in ultra-precision diamond turning. International Journal of Machine Tools and Manufacture, v. 69, p. 20-29.
XIAO. M.; SATO, K.; KARUBE, S.; SOUTOME, T. (2003) The effect of tool nose radius in ultrasonic vibration cutting of hard metal. International Journal of Machine Tools and Manufacture, v. 43, n. 13, p. 1375–1382.
XIAOLI, LI. (2002) A brief review: Acoustic emission methods for tool wear monitoring during turning. International Journal of Machine Tools and Manufacture, v. 42, n. 2, p. 157-165.
ZAHIA, H.; AHMED, B.; MOHAMED, A. Y.; TAREK, M.; JEAN-FRANÇOIS, R. (2013) On the prediction of surface roughness in the hard turning based on cutting parameters and tool vibrations. Measurement, v. 46, n. 5, p. 1671–1681.