The effect of cutting parameters on tool vibration during magnetorheological fluid controlled turning bar

Abstract

Tool vibration is a dynamic instability of the cutting process, which is a result of the interaction between the metal cutting process and the dynamics of a machine tool. The presence of such tool vibration leads to a poor surface finish, which results in cutting tool damage and the production of irritating and unacceptable noise. In order to reduce tool vibration, a magnetorheological fluid damper was developed that will respond to an applied field with a dramatic change in their rheological behaviour. The essential characteristic of these fluids is their ability to reversibly change from a free-flowing, linear, viscous liquid to a semi-solid with a controllable yield strength within milliseconds when exposed to a magnetic field. The present investigation aims to analyse the behaviour of a tool holder when attached with a magnetorheological damper during the turning operation using analytical and experimental methods. A Mathematical model was developed and the amplitudes of the tool vibration and chip thickness were calculated. Cutting experiments were conducted to study the effect of the magnetorheological damper on tool vibration, chip thickness etc. and to validate the results of the proposed mathematical model. From the results, it was observed that the use of the magnetorheological damper reduces tool vibration effectively and its results matches the results obtained from the numerical method.