Prediction of cutting tool vibration and surface roughness in hard turning of AISI52100 steel

Abstract

The changing behavior of vibration signals with varying cutting parameters (cutting speed, feed rate and depth of cut) for turning hardened AISI52100 steel has been studied and reported. The vibration response of cutting tool in all three mutually perpendicular directions, namely, in feed Vx, radial Vy and, tangential Vz directions have been captured by mounting piezoelectric tri-axial accelerometer close to the cutting tool. Experiments are planned and conducted as per Central composite rotatable design of Surface response methodology. The second order multiple regression models are developed to correlate cutting parameters with vibration acceleration and surface roughness. The coefficient of regression R2 for all models is found close to 0.92 which shows that the developed models are reliable and provide an excellent explanation between the cutting parameter and the vibration of cutting tool within limits. The analysis of the results revealed that cutting conditions are having prominent and mixed type effect on vibration signals. The acceleration amplitude Vx, Vy and Vz increases with increase in cutting speed, and depth of cut. The vibration amplitude Vx, Vy and Vz initially increases as feed increases and, with further increase in feed, the vibration amplitude decreases. The surface roughness is highly influenced by the feed rate followed by cutting speed whereas the depth of cut was found less significant. The fluctuation in frequency is observed in all directions. However, the band of frequency remains within a certain range. Within selected cutting parameter range, the maximum acceleration amplitude is observed in frequency band of 4 kHz-16 kHz.