Effect of magneto rheological damper on tool vibration during hard turning

Abstract

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

Key words： tool vibration; magneto rheological damper; hard turning; surface finish; tool wear

Acknowledgements

The authors are grateful to the Centre for Research in Design and Manufacturing Engineering (CRDM) of the School of Mechanical Sciences, Karunya University for facilitating this research work. The authors would like to thank Mr. Jones Robin, Mr. Jayakumar Rayappar and Mr. Sivasankaran of the machine tools laboratory for their help in conducting experiments. Authors also thank Tageu Tec. India (P) Ltd. for supplying cutting tools needed for this investigation.

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