Iranian Journal of Mechanical Engineering Transactions of the ISME

Iranian Journal of Mechanical Engineering Transactions of the ISME

The Optimum Design of an Anti-vibration Boring Bar by Improving Dynamic Characteristics

Document Type : Research Paper

Authors
Mahdi Hosseinpour 1
Abbas Rahi 2
1 M.Sc. Student, Faculty of Mechanical and Energy Engineering, Shahid Beheshti University, Tehran, Iran
2 Associate Professor, Faculty of Mechanical and Energy Engineering, Shahid Beheshti University, Tehran, Iran
10.30506/jmee.2024.2027496.1345
Abstract
Dynamic absorbers have many applications in reducing the undesirable vibration of the systems and can play a key role in suppressing the vibration but their performance is limited to a specific range of frequencies so they need to be optimized based on operation conditions. Due to the low stiffness of the long cantilever boring bar, vibration often occurs during the boring process. Vibration suppression by dynamic absorbers permits higher productivity and a better surface finish. To improve the performance of the boring bar operation, a variable stiffness dynamic absorber is added inside the boring bar to control and reduce the vibration. A boring bar equipped with a dynamic absorber can be tuned with different values of absorber length, diameter, stiffness, and installation position. This study modeled a boring bar with a long overhang equipped with a dynamic absorber and investigated the effect of each parameter on the stable cutting range of the boring process. By defining the stable cutting range of the boring bar as an objective function and the constraints of each parameter like the length, thickness, and chatter frequency, the optimum values of each parameter are determined by developing and using generated numerical analysis.
Keywords
Boring bar
Dynamic absorber
Transverse vibration
Natural frequency
Stiffness

Subjects

[1] G. Quintana, and J. Ciurana, “Chatter in Machining Processes: A Review,” International Journal of Machine Tools and Manufacture, Vol. 51, No. 5, pp. 363–376, May 2011, doi:10.1016/J.IJMACHTOOLS.2011.01.001.
 
[2] M. Siddhpura, and R. Paurobally, “A Review of Chatter Vibration Research in Turning,” International Journal of Machine Tools and Manufacture, Vol. 61, pp. 27–47, Oct. 2012, doi: 10.1016/J.IJMACHTOOLS.2012.05.007.
 
[3] C. Yue, H. Gao, X. Liu, S. Y. Liang, and L. Wang, “A Review of Chatter Vibration Research in Milling,” Chinese Journal of Aeronautics, Vol. 32, No. 2, pp. 215–242, 2019, doi: 10.1016/j.cja.2018.11.007.
 
[4] J. Ma, and Y. Ren, “Free Vibration and Chatter Stability of a Rotating Thin-walled Composite Bar,” Advances in Mechanical Engineering, Vol. 10, No. 9, pp. 1–10, 2018, doi: 10.1177/1687814018798265.
 
[5] D. I. Suyama, A. E. Diniz, and R. Pederiva, “The Use of Carbide and Particle-pamped Bars to Increase Tool Overhang in the Internal Turning of Hardened Steel,” International Journal of Advanced Manufacturing Technology, Vol. 86, pp. 2083–2092, Sep. 2016, doi: 10.1007/s00170-015-8328-z.
 
[6] P. Mihic, “Vibration - damped Tool Holder,” United States patent, U.S. Patent No. 8,020,474, Washington, DC: U.S. Patent and Trademark Office, Sep. 20, 2011, Available: https://patents.google.com/patent/US8020474B2.
 
[7] M. Sayuti, A. A. D. Sarhan, T. Tanaka, M. Hamdi, and Y. Saito, “Cutting Force Reduction and Surface Quality Improvement in Machining of Aerospace Duralumin AL-2017-T4 using Carbon Onion Nanolubrication System,” International Journal of Advanced Manufacturing Technology, Vol. 65, pp. 1493–1500, 2013, doi: 10.1007/s00170-012-4273-2.
[8] F. Xia, Z. Liu, and Q. Song, “Boring Bar with Constrained Damping,” Hangkong Xuebao/Acta Aeronautica et Astronautica Sinica, Vol. 35, No. 9, pp. 2652–2659, Sep. 2014, doi: 10.7527/S1000-6893.2013.0484.
 
[9] L. Daghini, A. Archenti, and C. M. Nicolescu, “Design, Implementation and Analysis of Composite Material Dampers for Turning Operations,” World Academy of Science, Engineering and Technology, International Journal of Mechanical and Mechatronics Engineering, Vol. 3, No. 5, pp. 613–620, 2009,  https://www.researchgate.net/publication/263887736_Design_Implementation_and_analyis_of_composite_material_dampers_for_turning_operations.
 
[10] V. J. Garcia, E. P. Duque, J. A. Inaudi, C. O. Márquez, J. D. Mera, and A. C. Rios, “Pendulum Tuned Mass Damper: Optimization and Performance Assessment in Structures with Elastoplastic Behavior,” Heliyon, Vol. 7, No. 6, Jun. 2021, doi: 10.1016/j.heliyon.2021.e07221.
 
[11] L. T. Tunc, and E. Budak, “Effect of Cutting Conditions and Tool Geometry on Process Damping in Machining,” International Journal of Machine Tools and Manufacture, Vol. 57, pp. 10–19, Jun. 2012, doi: 10.1016/j.ijmachtools.2012.01.009.
 
[12] A. Yu. Beregovenko, V. G. Kaplun, A. P. Yakovlev, and I. N. Pastukh, “Influence of Nitriding on Damping Properties of Some Metallic Materials,” Strength of Materials, Vol. 25, No. 8, pp. 604–609, Aug. 1993, doi: 10.1007/BF01151130.
 
[13] M. Sortino, G. Totis, and F. Prosperi, “Development of a Practical Model for Selection of Stable Tooling System Configurations in Internal Turning,” International Journal of Machine Tools and Manufacture, Vol. 61, pp. 58–70, 2012, doi: 10.1016/j.ijmachtools.2012.05.010.
 
[14] A. Rahi, and M. Hosseinpour, “Investigation of Dynamic Absorber Parameters to Improve the Vibration Behavior of Boring Bar,” Iranian Journal of Manufacturing Engineering, Vol. 9, pp. 1–8, 2022, doi: 10.22034/ijme.2022.163347.
 
[15] R. F. de Souza Filho, “Boring Bar with Improved Stiffness,” Inventor; Kennametal Inc, Assignee, U.S. Patent No. 10,040,127, Washington, DC: U.S. Patent and Trademark Office, Aug 7, 2018, Accessed: Jan. 20, 2023, Available: https://patents.google.com/patent/US20150258612.
 
[16] L. Li, B. Sun, and H. Hua, “Analysis of the Vibration Characteristics of a Boring Bar with a Variable Stiffness Dynamic Vibration Absorber,” Shock and Vibration, Vol. 2019, No. 1, 2019, doi: 10.1155/2019/5284194.
 
[17] R. L. Caslstedt, “Boring Bar,” U.S. Patent 3164041, Jan. 5, 1965, Available: https://patents.google.com/patent/US3164041A/en?oq=US3164041A.
 
[18] E. Abele, M. Haydn, and T. Grosch, “Adaptronic Approach for Modular Long Projecting Boring Tools,” Cirp Annals-Manufacturing Technology, Vol. 65, No. 1, pp. 393–396, 2016, doi: 10.1016/j.cirp.2016.04.104.
 
[19] I. Lazoglu, F. Atabey, and Y. Altintas, “Dynamics of Boring Processes: Part III-time Domain Modeling,” International Journal of Machine Tools and Manufacture, Vol. 42, No. 14, pp. 1567-1576, 2002, doi: https://doi.org/10.1016/S0890-6955(02)00067-6.