Experimental Analysis of the Influence of Depth of Cut, Time of Cut, and Machining Speed on Vibration Frequency during Turning of AL1060 Alloy

Abstract

Machining vibration is a significant concern in the manufacturing industry, as vibration cannot be eliminated during metal to metal turning operations. It can be controlled to the minimum when a proper study is carryout before the turning process. This study aims to experimentally analyse the effect of the individual parameters such as depth of cut (DOC) and cutting speed have on the machining vibration during turning of AL1060 alloy. A computer numerical control (CNC) program was applied to investigate the effects of the different depths of cut such as 1 mm, 1.5 mm, 2 mm, 2.5 mm, and 3 mm. Moreover, cutting speed of 200 m/min, 350 m/min, 500 m/min, and 600 m/min with a constant feed rate of 5 mm/rev have on the machining vibration during the turning process. DTO 32105 frequency analyser an MXC-1600 digital frequency counter was employed to measure the machining vibration for a specific time between 15 seconds to 500 seconds. The result shows that as the depth of cut continually increases, the machining vibration increases and the minimum machining vibration of 131.8 Hz was obtained at cutting speed of 600 m/min, depth of cut of 1 mm, and cutting time of 15 sec. The Pareto chart was further used to analysis the average vibration frequency at the optimised cutting speed of 600 m/min. The surface quality and the cutting tool life can be significantly enhanced with the study of the individual machining parameters.