The survey damping ability of the milling cutting tool with the inverted conxol model

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT ELECTRONICS AND TELECOMMUNICATIONS ENGINEERING TECHNOLOGY THE SURVEY DAMPING ABILITY OF THE MILLING CUTTING TOOL WITH THE INVERTED CONXOL MODEL LECTURER: ME Le Ba Tan STUDENT: TRAN CAO LONG NGUYEN ANH TU NGUYEN DINH HIEU S K L 01 Ho Chi Minh City, 2023 HCMC UNIVERCITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS THE SURVEY DAMPING ABILITY OF THE MILLING CUTTING TOOL WITH THE INVERTED CONXOL MODEL STUDENTS’ NAME & ID: Tran Cao Long Nguyen Anh Tu Nguyen Dinh Hieu ADVISOR: ME Le Ba Tan – 18144035 – 18144059 – 18144017 HCM City, July, 2023 ii TABLE OF CONTENTS LIST OF FIGURES vi LIST OF TABLES ix PREFACE xii ABSTRACT xiii Chapter 1: OVERVIEW The urgency of the topic Published domestic and foreign research results Goal of the topic Tasks and range of the project Tasks of the project Range of the project Research methods Chapter 2: THEORETICAL BASIS Metal cutting theoretical foundations Characteristics and role of metal cutting The fundamental tool actions during cutting Feed movement and quantity Extra movement and cut depth Milling technology theoretical underpinnings A summary of milling processing techniques Milling tool types Technology capabilities for milling 11 Machined part surface roughness 12 Theories 12 The influence of surface roughness 13 Criteria for evaluation 15 iii Symbols and callouts for surface roughness on drawings 18 Choosing the Surface Roughness 22 Surface roughness factors 22 Surface roughness generation method 23 Surface roughness evaluation method 23 Vibration during the cutting process 23 Overview of cutting vibration 23 Vibration types and causes 23 Vibration reduction solution 25 Creating an integrated dampening system for cutting tools 27 An Overview of the Damping Cutting Tool 27 Milling technology with dampers cutter handle 28 Optimization method 35 Taguchi method 35 ANN_GA method 37 Chapter 3: EMPIRICAL STUDY OF THE EFFECT OF DAMPINGING CUTTER HANDLES ON DETAILED SURFACE GLOSS 39 Experiment conditions 39 Cutting conditions 39 Length of cutter 40 CNC machine VM750 41 Experiment procedure 41 The meaning of the parameters: 41 Investigate the influence of L on the surface gloss of the workpiece: 42 Investigate the influence of l on the surface gloss of the workpiece: 42 Investigate the influence of ∅ on the surface gloss of the workpiece: 43 Investigate the influence of R on the surface gloss of the workpiece: 43 Investigate the influence of d on the surface gloss of the workpiece: 44 Investigate the influence of h on the surface gloss of the workpiece: 44 iv Damping cutting tools and damping cores 45 Workpieces 48 Measuring instrument 49 Cases for experimentation 51 Experiments process and Results 53 Measuring and comparing surface roughness results 53 Optimization method 61 Chapter 4: VIBRATION ANALYSIS METRICS OF MILLING TOOL 73 The peak, peak to peak and RMS values in vibration analysis 73 Peak value 73 Peak to peak value 73 RMS 75 4.2 Measuring equipment and working principle 77 Conclusion on the vibration analysis metrics of milling tool 80 Chap CONCLUSION AND FURTHER RESEARCH DIRECTION 84 5.1 Conclusion 84 5.2 Further research direction 84 REFERENCES 85 v LIST OF FIGURES Figure 2.1: Technology system [7] Figure 2.2: Basic movement of tool when milling [7] Figure 2.3: Reverse milling [8] Figure 2.4: Forward milling [8] Figure 2.5: Cylindrical milling cutter [9] 10 Figure 2.6: Angle milling cutter [9] 10 Figure 2.7: Disc milling cutter [9] 10 Figure 2.8: End milling cutter [9] 10 Figure 2.9: Milling process capabilities [9] 11 Figure 2.10: Types of undulations on the detailed surface [10] 13 Figure 2.11: Effect on wear resistance [10] 13 Figure 2.12: Effect on fatigue strength of parts [10] 14 Figure 2.13: Effect on corrosion resistance [10] 14 Figure 2.14: Effect on corrosion resistance 15 Figure 2.15: Surface profile [10] 16 Figure 2.16: Surface profile [10] 16 Figure 2.17: Surface roughness note definitions (EN ISO 1302) [11] 18 Figure 2.18: How to Read Surface Texture Requirements [11] 19 Figure 2.19: Texturing on contour lines that depict surfaces [11] 20 Figure 2.20: Dimensional feature - surface texture required [11] 20 Figure 2.21: Indication of geometrical tolerances [11] 21 Figure 2.22: cyclindrical feature extensions lines [11] 21 Figure 2.23: Surfaces with cyclindrical and prismatic symmetry [11] 22 Figure 2.24: Crop angle influences stability [12] 30 Figure 2.25: Insert fragment types [12] 30 Figure 2.26: Large teeth step cutting tools [12] 31 Figure 2.27: Medium tooth step cutting tools [12] 31 Figure 2.28: Small teeth step cutting tools [12] 32 Figure 2.29: Face milling general guidelines [13] 32 Figure 2.30: Forward milling and reverse milling [13] 33 Figure 2.31: The cutting edge of inserts [14] 34 Figure 2.32: Insert rake angle [14] 34 Figure 2.33: Inserts fragment cut angle [13] 35 Figure 2.34: Diagram for static problem [15] 36 vi Figure 2.35: ANN_GA optimization method [17] 38 Figure 3.1: Recommended cutting condition of inserts 40 Figure 3.2: Length of tool holder and cutter 40 Figure 3.3: CNC machine VM750 41 Figure 3.4: Damping cutting tool 45 Figure 3.5: Insert APMT1135PDER parameters 46 Figure 3.6: Damping compliance 47 Figure 3.7: Custom damping compliance holder 47 Figure 3.8: Damping cutting tool assembly 48 Figure 3.9: Experiment samples 49 Figure 3.10: Mitutoyo SJ-201 roughness meter 50 Figure 3.11: Mitutoyo SJ-201 roughness meter [19] 50 Figure 3.12: Definitions for parameters of damping compliance 51 Figure 3.13: Measuring Ra value 53 Figure 3.14: Results after measuring 53 Figure 3.15: Comparision of normal tool and damping compliance to 55 Figure 3.16: Comparision of normal tool and damping compliance to 56 Figure 3.17: Comparision of normal tool and damping compliance to 12 57 Figure 3.18: Comparision of normal tool and damping compliance to 12 58 Figure 3.19: Comparision of normal tool and damping compliance 17 to 20 59 Figure 3.20: Comparision of normal tool and damping compliance 21 to 25 60 Figure 3.21: Analyze Taguchi Design 61 Figure 3.22: Choosing factors 62 Figure 3.23: Choosing response data 63 Figure 3.24: Main effect for means 63 Figure 3.25: Input and target variables 64 Figure 3.26: Neural Network/Data Manager 65 Figure 3.27: Import Input Data 65 Figure 3.28: Import Target Data 66 Figure 3.29: Create new neural network 66 Figure 3.30: Prepare data and function for new neural network 67 Figure 3.31: Training network 68 Figure 3.32: Neural network training regression 69 Figure 3.33: Fitness function code 70 Figure 3.34: Optimization setup in Matlab 70 Figure 3.35: ANN_GA method results 70 vii Figure 3.36: Comparison surface roughness of optimal damping tool and normal tool 71 Figure 4.1: Waveform chart of peak values 73 Figure 4.2: Waveform chart of peak to peak values 74 Figure 4.3: The formula of RMS values 75 Figure 4.4: Waveform chart of RMS values 76 Figure 4.5: Waveform chart of RMS values of velocity 76 Figure 4.6: Waveform chart of RMS values with critical level 77 Figure 4.7: Milling cutting tool deformation measurement model 78 Figure 4.8: Dynamox TCas vibration and temperature sensor 79 Figure 4.9: The chart of peak to peak values of acceleration on axial 80 Figure 4.10: The chart of peak to peak values of acceleration on radial 80 Figure 4.11: The chart of peak to peak values of acceleration on horizontal 81 Figure 4.12: The chart of peak to peak values of displacement on axial axis 82 Figure 4.13: The chart of peak to peak values of displacement on radial axis 82 Figure 4.14: The char of peak to peak values of displacement on horizontal axis 83 viii LIST OF TABLES Table 2.1: Surface roughness parameter values (ISO 12085:1996) [10] 17 Table 2.2: Standard values of Ra and Rz [10] 18 Table 2.3: Surface roughness value according to the dimensional accuracy grade [10] 22 Table 3.1: Experiments conditions 39 Table 3.2: Parameters of damping compliance when changing L variable value 42 Table 3.3: Parameters of damping compliance when changing l variable value 43 Table 3.4: Parameters of compliance when changing Ø variable value 43 Table 3.5: Parameters of compliance when changing R variable value 44 Table 3.6: Parameters of compliance when changing d variable value 44 Table 3.7: Parameters of compliance when changing h variable value 45 Table 3.8: Basic component of high-speed steel [18] 45 Table 3.9: High-speed steel heat treatment [18] 46 Table 3.10: Chemical compositions and mechanical properties of SS400 steel 48 Table 3.11: All damping cases dimensions 52 Table 3.12: Surface roughness for each cases 54 Table 3.13: Average surface roughness of normal cuttin tool 55 Table 3.14: Parameters and surface roughness of compliance to 55 Table 3.15: Parameters and surface roughness of compliance to 56 Table 3.16: Parameters and surface roughness of compliance to 12 57 Table 3.17: Parameters and surface roughness of compliance 13 to 16 58 Table 3.18: Parameters and surface roughness of compliance 17 to 20 59 Table 3.19: Parameters and surface roughness of compliance 13 to 16 60 Table 3.20: Parameters of optimized damping cutting tool 71 Table 3.21: Surface roughness of optimized damping tool and normal tool 71 ix TRƯỜNG ĐẠI HỌC SƯ PHẠM KỸ THUẬT TP HCM CỘNG HOÀ XÃ HỘI CHỦ NGHĨA VIỆT NAM KHOA ĐÀO TẠO CHẤT LƯỢNG CAO Độc lập - Tự – Hạnh phúc NHIỆM VỤ ĐỒ ÁN TỐT NGHIỆP Học kỳ 2/ năm học 2023 Giảng viên hướng dẫn: ThS Lê Bá Tân Sinh viên thực hiện: Trần Cao Long Nguyễn Anh Tú MSSV: 18144035 Điện thoại: 0974101422 MSSV: 18144059 Điện thoại: 0362619574 Nguyễn ĐÌnh Hiếu MSSV: 18144017 Điện thoại: 0335644970 Tên đề tài: Khảo sát khả giảm chấn cán dao phay với mơ hình conxol gắn ngược Các số liệu, tài liệu ban đầu: - Sử dụng phần mềm MATLAB cho tối ưu hóa - Sử dụng dụng cụ đo độ nhám bề mặt - Sử dụng cán dao BAP300R C20-20-160-2T - Vật liệu phơi: SS400 Nội dung đồ án: - Tổng quan công nghệ phay chất lượng bề mặt - Chế tạo mơ hình cán dao phay - Lắp ráp thực đo lường độ bóng bề mặt - Tổng hợp số liệu báo cáo Các sản phẩm dự kiến - Mơ hình thực tế - Báo cáo phân tích liệu Ngày giao đồ án: 15/03/2023 x M6 15 Technical requirements: - Cylindricity