OVERVIEW
The urgency of the topic
As we navigate the fourth industrial revolution, the precision mechanical processing sector must adhere to increasingly stringent accuracy standards while ensuring high efficiency and product quality This demand presents significant challenges for precise machining, particularly when high-speed machining is essential for productivity The necessity for thicker cuts during this process often leads to increased vibration and noise, which can compromise cutting tool integrity and hinder surface quality.
Mechanical processing, particularly milling, is often accompanied by significant vibration and noise To mitigate these issues, operators frequently reduce machining parameters such as spindle speed, cutting speed, tooth feed amount, and depth of cut, which can negatively impact productivity This research article proposes the integration of dampening instruments into the machining process to effectively reduce vibration while maintaining essential process parameters and productivity levels Furthermore, end mills facilitate adherence to technical specifications regarding insert shape, gloss, product roughness, and cutting equipment requirements When machining outer profiles, longer tool shank lengths are unnecessary, as CNC machines manage movement, and the machining profile length is limited by the machine shaft's displacement capabilities However, using long-shank milling cutters complicates achieving a high-gloss finish, as increased shank length reduces stiffness, leading to greater vibration and noise that adversely affect the product's form, gloss, and surface quality.
Stemming from the above reasons, our group has deeply researched, researched and implemented the topic: “THE SURVAY DAMPING ABILITY OF THE MILLING
CUTTING TOOL WITH THE INVERTED CONXOL MODEL" for graduation project
Published domestic and foreign research results
Numerous studies have examined how technological factors influence overall detail quality; however, this group's focus is specifically on how tools affect surface gloss.
- Subject: Clarence W de Silva, Vibration Damping, Control, and Design, April
- Application of Taguchi method in optimization of end milling parameters by J.A Ghani, I.A Choudhury, H.H Hassan – University Malaysia [3]
- Subject: "Study on the effect of cutting mode on surface roughness when machining on CNC milling machines" by Truong Thi Ngoc Thu - University of
Advantages: Determine the effect of cutting mode on surface roughness with independent variables (S,t)
State the influence relationship of cutting mode (S,t) to surface roughness
The research outcomes are limited as they do not consider additional factors such as tool wear, different processing materials, and the rigidity of the technological system, which can significantly influence results These evaluations are conducted solely under specific experimental conditions, potentially overlooking critical variables that affect performance.
This article presents an experimental study conducted by Ngo Duc Hanh from Thai Nguyen University, focusing on the properties of self-excited vibrations in metal cutting processes The research investigates how varying feed rates influence the growth of these vibrations, utilizing advanced computer analysis The findings aim to enhance understanding of vibration dynamics in machining, ultimately contributing to improved precision and efficiency in industrial engineering practices.
Advantages: Identify types of vibration and causes of vibration on machine tools Disdvantages: There is no optimal method to minimize the vibrations that occur when machining on machine tools
- Subject: "Research to improve the surface quality of machine parts when finishing milling" by Hoang Trong Hieu - University of Da Nang [6]
Advantages: There is a sufficient theoretical basis for the phenomena occurring during cutting
Comment in detail on the direct relationship between cutting speed and feedrate and the workpiece's surface
Disadvantages: Have not changed the machining parameters, perform experiments on a certain parameter
Many surface quality tests have been performed by leading global brands such as Mitsubishi, Hutscom, Tungaloy, and Walter These evaluations are generally conducted on standard materials and under optimal machining conditions, resulting in ideal outcomes Additionally, these studies align with the commercial goals of the manufacturers, as evidenced by their presentations in catalogs and trade shows showcasing their technology.
However, no investigations on the impact of dampening tool holders on the surface gloss of facet milled parts have been published
- An overview study of damping technology in metalworking
This article explores the fabrication and experimentation of a milling cutter shank featuring an integrated damping system, focusing on its impact on surface gloss when altering the internal parameters of the damper shank on C45 steel material in Vietnam The study also compares the performance of this advanced cutting tool with that of a conventional milling cutter.
- Explain which variables affect surface quality when a damper shank with an integrated damping system is used
Tasks and range of the project
The research direction contains the following duties, starting with the topic's title and its stated purpose:
- A theoretical framework for understanding metal cutting, the quality of machined surfaces, and the variables that influence these qualities
- The causes of vibration, how vibration affects machining quality, and possible strategies to eliminate vibration are all covered in the theory of vibration in machining
- Creation of a milling cutter shank with a built-in dampening system
- Set up the experimental procedure
Prepare workpieces, 2 types of shank (regular and damping) and inserts
Prepare machines, tools and test cutting to check whether the technology system is ok, is the cutter well mounted?
Process data, make graph and compare, analyze and evaluate the results
The following describes the study's scope due to time and resource constraints:
- The sample was milled in the mechanical workshop using CNC milling machine
- The test was conducted on only one end mill cutter BAP 300R C20-20-2L160-
- Use insert: APMT1135PDER-HT from DESKAR
This study focuses exclusively on SS400 steel, analyzing how modifications to the internal design parameters of the damping core affect surface gloss The investigation utilizes the manufacturer's recommended cutting parameters, specifically a feed rate of 0.15 mm per tooth.
Vc = cutting speed = 200mm/min t = depth of cut = 0.75mm
- Milling and measuring gloss on the surface of SS400 steel material
- Use damping end mill (BAP 300R C20-20- 2L160-1135 19E13) and a normal end mill (BAP 300R C20-20-2L150-1135 19E13) with diameter of Dc = 20 mm
- Experiment on CNC milling machine Doosan VM750 in the mechanical workshop
- Utilizing Matlab and Minitab to optimized damping compliance parameters using Taguchi and ANN_GA method
- Measure surface roughness with Mitutoyo SJ-201 handheld roughness meter
- Create a table of the findings and a graph comparing the roughness of surfaces milled using a regular cutting tool and a damping cutting tool under the same milling settings
THEORETICAL BASIS
Characteristics and role of metal cutting
There are several metal cutting technologies available today: casting, forging, rolling, welding but these methods mostly produce billets or primitive products, frequently with low precision and gloss
Metal cutting machining is required to improve the gloss and precision of the items in accordance with the technical requirements
Metal cutting is a precise technological process that transforms raw workpieces into mechanical products by removing metal layers in the form of chips, achieving desired shapes, sizes, and surface finishes.
The machining is done at room temperature (both before and after the heat treatment process) It produces more gloss and accuracy than welding, casting, forging, and hot stamping
Turning, milling, planing, drilling, boring, boring, broaching, and grinding are the basic metal cutting procedures
Cutting machining accounts for 30% of mechanical machining workloads and may account for more in the future
A technological system is the collection of equipment required to execute the cutting process, which includes: Machine Workpiece - Fixture - Cutting Tool
The machine provides essential energy for cutting operations, while the jigsaw ensures the accurate alignment of the tool, machine, and workpiece throughout the machining process Additionally, the tool is responsible for swiftly removing the excess metal layer from the component.
Machine Cutting tool Fixture Workpiece using the machine's energy given by relative motions
The cutting process is focused on the work item All cutting process outcomes are represented on the work piece
The fundamental tool actions during cutting
Each metal cutting machine has a unique path of relative motion between the tool and the component There are three kinds of movement:
The primary cutting motion refers to the essential movement of the cutter as it interacts with the cutting tool or workpiece This motion can involve rotation, linear translation, or a combination of both, playing a crucial role in the machining process.
In machining processes, the primary movement involves the rotation of the workpiece on the chuck during turning For milling, drilling, and grinding, the main motion is the circular movement of the milling cutter, drill, or grinding wheel In planning and cutting, the tool's reciprocating and vertical actions are crucial Tool motion refers to the movement of the tool or workpiece that complements the primary movement essential for the cutting process.
The movement of the feed might be continuous or intermittent This movement is typically performed in a direction perpendicular to the primary movement, more precisely:
- The feed movement during turning is the horizontal - vertical movement of the tool table when cutting
- Milling is the horizontal-vertical-vertical movement of the workpiece-carrying table
- The horizontal (vertical) movement of the table and the up and down movement of the tool head while grinding
- The transverse (vertical) reciprocating motion of the table or the axis of the grinding wheel while grinding
- When drilling, the drill bit moves downward
Extra motion is defined as any movement that does not directly create the chip, such as forward and backward motion (without cutting into the workpiece).
Figure 2.2: Basic movement of tool when milling [7]
We utilize two quantities to characterize the primary motion:
The relative displacement over time between the cutting edge and the workpiece, or between a specific point on the workpiece surface and the cutting edge, is determined by the number of revolutions (or double strokes) executed within a given time unit.
The feed rate refers to the distance traveled by the cutting edge in relation to the workpiece during a specific time frame, such as one revolution of the workpiece or a double stroke This measurement can be expressed in various units, including circular or minute values, highlighting its versatility in machining processes.
The feed rate s in turning is the amount of tool movement along the work surface per rotation of the workpiece (mm/round)
The feed amount s while planning and cutting is the amount of displacement of the tool or table following a double stroke of the table (or tool) - mm/double stroke
Calculating the feed rate for multi-blade tools, such as milling cutters, can be done in three ways: the feed rate per tooth (mm/tooth), the feed rate per revolution of the tool (mm/rotation), and the feed rate per minute of operation (mm/min).
Extra movement and cut depth
The amount of metal removed following a cut (or the distance measured perpendicular to the toolpath between two adjacent machinable and unmachinable surfaces)
The cutting mode refers to the combination of parameters such as cutting speed
V, depth of cut t, and feed rate S
A summary of milling processing techniques
Milling is a metalworking process that utilizes a cutter equipped with multiple cutting blades The primary motion of the tool is circular, while the table provides horizontal, vertical, and lateral feed movements.
The milling cutting speed is computed using the formula:
- D: Diameter of milling tool (mm)
One of three criteria determines the amount of feed used in milling:
- The tooth feed amount (Sz) is the displacement of the component when one milling cutter tooth (1 cutting edge) enters the metal; the unit is mm/teeth
- The feed rate (Sv) is the displacement of the component when the milling cutter turns one revolution It is represented by Sv and is measured in millimeters per revolution
- The minute feed rate (Sm) is the displacement of the component after one minute, represented by Sm and measured in mm/min
Thus, the relationship between the above feed rates is as follows:
Sm = Sv.n = Sz.Z.n [mm/min] [7]
- Z: number of teeth (number of blades) of milling tool
- n: number of revolutions of tool in one minute
When milling, there are two options:
- Forward milling occurs when the forward motion of the workpiece corresponds with the rotational direction of the tool
- Reverse milling is the direction of motion of the workpiece against the rotation of the tool
During forward milling, the thickness of the cutting component decreases from a maximum to zero, resulting in a higher surface finish due to the lack of slippage between the milling cutter and the workpiece In contrast, back-milling experiences less impact on the cutter, minimizing machine and tool damage, making it more suitable for rough milling applications.
The Benefits of Reverse Milling implies that the length of the cutting grows from amin
The cutting force gradually increases from 0 to amax, preventing collisions The forward-directed force stimulates the interaction between the nut and the lead screw of the machine table, effectively minimizing vibrations.
Reverse milling has notable drawbacks, primarily due to the initial cutting thickness of a new tooth being set at amin = 0 This leads to sliding between the cutting edge and the machined surface, resulting in poor surface smoothness and accelerated tool wear Consequently, reverse milling is primarily restricted to roughing applications.
Forward milling offers significant advantages, including the absence of slippage when the fresh cutting edge engages the material This process utilizes a blade thickness that varies from amax to amin, which contributes to reduced tool wear and extended lifespan Additionally, forward milling ensures exceptional surface smoothness, making it a preferred choice in machining applications.
Forward milling has notable drawbacks, including potential collisions during the cutting process, brittleness of the cutter, and elevated vibration levels Additionally, the cutting force directed in the feed direction leads to a discontinuous contact between the lead screw and the table nut, further complicating the milling operation.
When we cut with a thin blade, the modest impact force has little effect on the vibration
Milling cutters differ from turning tools as they feature multiple cutting edges, which can be integrated into the tool body or designed as separate chamfer teeth These cutting edges may be positioned on the cylinder face, the end face, or both Milling cutters are categorized into various types based on insert shape, blade location, and construction.
Cylindrical milling cutters are tools with cutting edges located on their cylindrical surfaces, and they come in two main types: straight tooth and inclined tooth milling cutters Straight tooth milling cutters have their primary cutting edge aligned parallel to the tool axis, while inclined tooth milling cutters possess a primary cutting edge that is angled relative to the tool axis.
- Face end mills are milling cutters with the cutting edge placed on the tool's face
End face milling cutters can have solid teeth or connected teeth
- End mills can have two to eight cutting edges
- Milling cutter with a disc milling cutter with an angle
For gear processing, there are also Inserts-defined milling cutters, keyway milling cutters, and modular tooth roller milling cutters
EMPIRICAL STUDY OF THE EFFECT OF DAMPINGING CUTTER
DAMPINGING CUTTER HANDLES ON DETAILED SURFACE
The same cutting circumstances are maintained throughout the experiment because our group's sole focus in this study was the surface roughness when damping compliance was changed
Holder Insert Relief angle Cutting edge radius
Cutting speed Spindle speed Feed rate Depth of cut
According to recommended cutting conditions from manufacturer and because SS400 steel is low alloy, choose Cutting Speed: Vc = 200 (m/min) and Feed per Tooth: n = 0.15 (mm/tooth) n = 1000 × Vc π × Dc ;
Figure 3.1: Recommended cutting condition of inserts Length of cutter
Length of cutter also affects roughness of machined surface The length of both would be uniform as follow:
- Length of tool holder: L1 = 110 mm
- Total length from head stock to cutter: L = L1 + L2 = 110 + 80 = 190 mm
Figure 3.2: Length of tool holder and cutter
- Safety mechanisms according to European standards
The meaning of the parameters:
The article discusses the implementation of a vibration-absorbing structure for cutting tools, which includes a mass and a connecting element This innovative mechanism led to the development of the Conxol, featuring adjustable parameters to optimize performance.
Figure 3.4: Conxol model and the variable values
The groove between the conxol acts as a connecting element The values of R, i and d can change the shape of groove that can influence the ability to absorb vibration
The values of L, h, and ỉ will change the mass of conxol That also can influence the ability to absorb vibration
Investigate the influence of L on the surface gloss of the workpiece:
Find out how changing L in the damper rods affects the gloss of the workpiece
There are 4 cases begin from L = 80mm and then reduce L until the dimension reach L
Table 3.2: Parameters of damping compliance when changing L variable value
Before proceeding with milling the workpiece, ensure the installation of each damping compliance with a specific L value After milling each case, use a measuring device to assess the workpiece's gloss and collect the values for comparison.
Investigate the influence of l on the surface gloss of the workpiece:
Find out how changing l in the damper rods affects the gloss of the workpiece
There are 4 cases begin from l = 35mm and then reduce with 5 mm step until the dimension reach l = 15mm
Table 3.3: Parameters of damping compliance when changing l variable value
Install each damper, ensuring that each has a unique length, and continue milling the workpiece afterward Use a measuring device to assess the surface roughness of the workpiece after milling each instance, and compile the values for comparison.
Investigate the influence of ∅ on the surface gloss of the workpiece:
Find out how changing l in the damper rods affects the gloss of the workpiece
There are 4 cases begin from ∅= 8mm and then reduce with 0.5 mm step until the dimension reach ∅=6mm
Table 3.4: Parameters of compliance when changing ỉ variable value
After milling the workpiece, install each damping compliance with varying diameters Use a measurement device to assess the shine of the finished workpiece, and then collect data for comparison purposes.
Investigate the influence of 𝐑 on the surface gloss of the workpiece:
Find out how changing l in the damper rods affects the gloss of the workpiece
There are 4 cases begin from R= 2.5mm and then reduce with 0.25 mm step until the dimension reach R=1.5mm
Table 3.5: Parameters of compliance when changing R variable value
Before proceeding with the milling of the workpiece, ensure that each damping compliance with a unique R value is installed After milling each case, use a measuring device to assess the gloss of the workpiece, and collect the values for comparison.
Investigate the influence of 𝐝 on the surface gloss of the workpiece:
Find out how changing l in the damper rods affects the gloss of the workpiece
There are 4 cases begin from d= 2mm and then reduce with 0.25 mm step until the dimension reach d=1mm
Table 3.6: Parameters of compliance when changing d variable value
Before proceeding with milling the workpiece, ensure that each damping compliance with varying dimensions is properly installed After milling each case, use a measuring device to assess the gloss of the workpiece and collect the values for comparison.
Investigate the influence of 𝐡 on the surface gloss of the workpiece:
Find out how changing l in the damper rods affects the gloss of the workpiece
There are 5 cases begin from h = 14 mm and then reduce until the dimension reach h 0 mm
Table 3.7: Parameters of compliance when changing h variable value
Before proceeding with the milling of the workpiece, ensure the installation of each damping compliance with varying heights After milling each case, use a measuring device to assess the workpiece's shine, collect the values, and prepare them for comparison.
Damping cutting tools and damping cores
The BAP30254S25 milling cutter is crafted from high-speed steel, known for its exceptional heat resistance and hardness due to its highly alloyed steel composition This type of steel is favored globally for its ability to facilitate rapid cutting while maintaining the toughness of the cutting tool, making it an ideal choice for efficient machining processes.
Table 3.8: Basic component of high-speed steel [18]
Table 3.9: High-speed steel heat treatment [18]
Figure 3.5: Insert APMT1135PDER parameters
Figure 3.5: Specifications of the APMT1135PDER insert
Figure 3.7: Custom damping compliance holder
Figure 3.8: Damping cutting tool assembly
SS400, classified under the JIS G3101 standard, is a widely used structural steel grade characterized by its tensile strength of 400 MPa The designation 'S' signifies 'Steel' and 'Structure,' indicating its primary application in various structural components This versatile steel is essential in the manufacturing of auxiliary materials for machines and structures, including steel plates, bars, and sections, making it integral to constructions such as bridges, ships, and automobiles.
SS400, known for its low carbon content, exhibits mild hardness, making it unsuitable for primary components requiring high wear resistance, strength, or hardness However, it excels in machinability and weldability, making it ideal for applications such as welding nuts, small parts, and structural components in the automotive and machinery sectors It is often utilized as an auxiliary material in various construction and machine applications.
Table 3.10: Chemical compositions and mechanical properties of SS400 steel
In this milling process, all damping cases will be applied to both sides and along the length of the workpiece, using perpendicular milled paths A standard cutter, along with enhanced damping compliance, will be employed to mill the entire length, while two routes will be processed utilizing 25 different damping cases.
Some Mitutoyo SJ-201 roughness meter features:
- Large characters are displayed on the large easy-to-view LCD
- Portable for easy measurement anywhere necessary
- The detector/drive unit can be detached from the display unit for effortless measurement of awkwardly oriented workpieces
- Roughness parameters compatible with ISO, DIN, ANSI, and JIS
- 19 analysis parameters are provided, including the basic Ra, Rq, Rz, and Ry parameters
- GO/NG judgment on a desired parameter
- Auto-calibration for simple gain-adjustment
- Auto-sleep function saves energy
- 10 Measurement data is retained in memory even after the power is turned off
- A precision roughness specimen is supplied
Figure 3.10: Mitutoyo SJ-201 roughness meter
Figure 3.11: Mitutoyo SJ-201 roughness meter [19]
Optimizing experimental conditions is essential for developing effective analytical methods The common approach of examining each factor individually (one factor at a time) is straightforward but may not yield the best overall results This method can overlook the interactions between variables, leading to suboptimal conditions As a result, the univariate technique has emerged as a popular and efficient solution for addressing these limitations in the optimization process.
Figure 3.12: Definitions for parameters of damping compliance
To create an effective soft damping for milling, we start by identifying six key variables and five typical values We apply the Taguchi statistical method, which aims to minimize quality deviations in the process or product, ensuring consistent high-quality outcomes This approach allows us to generate 25 real-world examples, all of which will undergo milling to obtain initial results We then analyze the data using two distinct optimization techniques Once the desired outcomes are achieved, we mill two optimal examples, compare the latest results, and draw conclusions based on our findings.
Table 3.11: All damping cases dimensions
Measuring and comparing surface roughness results
To accurately measure surface roughness using the Mitutoyo SJ-201, it is essential to place the detector on a stable and rigid surface, preferably a stone table, to minimize vibrations Position the probe head of the detector as close as possible to the sample's surface for precise measurements.
Measurements will be taken three times on each damping case with tolerance of 0.03 μm From there, average surface roughness results are obtained:
Table 3.12: Surface roughness for each cases
With the same cutting mode as above, we proceed on a normal cutter and get the following results:
Table 3.13: Average surface roughness of normal cuttin tool
In analyzing the performance of various tools, the normal tool exhibited values of 1.974, 1.703, 1.921, and 1.87, while the tool without compliance showed values of 1.68, 2.14, 2.1, and 1.97 These results enable risk-free comparisons; however, to enhance the assessment of damping compliances' surface roughness relative to a standard cutting tool, it is essential to categorize the damping compliances into distinct groups.
Group 1: Different total length L (mm) value
Table 3.14: Parameters and surface roughness of compliance 1 to 4
Figure 3.15: Comparision of normal tool and damping compliance 1 to 4
Most of damping compliances give worse surface roughness than normal tool with exception of compliance 1 (L = 80 mm) with Raavg = 2.03 μm has higher roughness
Whereas compliance 3 (L = 65 mm) gives better result with Raavg = 1.93 μm The roughness better than tool without compliant Raavg = 1.97 μm
Group 2: Different first section length l (mm) value
Table 3.15: Parameters and surface roughness of compliance 5 to 8
Figure 3.16: Comparision of normal tool and damping compliance 5 to 8
Most of damping compliances give worse surface roughness than normal tool with exception of compliance 7 (l = 20 mm) with significantly higher Raavg = 2.21 μm and compliance 8 (l = 15 mm) has slightly higher Raavg = 1.81 μm Meanwhile, compliance
5 and 6 gives better result with Raavg = 1.59 μm The roughness better than tool without compliant Raavg = 1.97 μm
Group 3: Different compliance diameter ỉ (mm) value
Table 3.16: Parameters and surface roughness of compliance 9 to 12
Figure 3.17: Comparision of normal tool and damping compliance 9 to 12
VIBRATION ANALYSIS METRICS OF MILLING TOOL
Measuring equipment and working principle
Measuring equipment: Milling cutting tool deformation measurement model
The machine features a table equipped with a turntable and metal bars, which is linked to a step motor via a belt Its body contains a shaft resembling a milling machine spindle, designed for collet attachment Additionally, a sensor is mounted directly on the spindle to gather data effectively.
Figure 4.7: Milling cutting tool deformation measurement model7
The TcAs DynaLogger features two distinct monitoring modes: spectral/waveform and telemetry Its telemetry monitoring is band configurable and provides a range of metrics, including acceleration, velocity, and displacement measured in RMS, peak, peak-to-peak, and crest factor, along with skewness, kurtosis, and contact temperature In spectral monitoring, users can utilize various tools such as spectrum analysis, waveform (linear, circular, and orbital), frequency filters, cepstrum, spectral envelope (demodulation), autocorrelation, and multi-metrics analysis.
Figure 4.8: Dynamox TCas vibration and temperature sensor8
- The rotary table at the bottom will rotated by step motor
- The metal bars collide with the cutting tool to create the vibration and transmit to sensor
- The sensor on top will collect the parameters such as acceleration and displacement and send the result to cloud
Conclusion on the vibration analysis metrics of milling tool
4.3.1 Comparison PP value of acceleration
Figure 4.9: The chart of peak to peak values of acceleration on axial9
Cases 15 and 26 of cases which have conxol structure have the lowest peak to peak values of acceleration on axial axis
Figure 4.10: The chart of peak to peak values of acceleration on radial10
Case normal tool has the lowest peak to peak values of acceleration on radial axis
Figure 4.11: The chart of peak to peak values of acceleration on horizontal11
Case 11 of cases which have conxol structure has the lowest peak to peak value of acceleration on horizontal axis
Conclusion: Cases conxol 15,26 and 11 have the PP value of acceleration are more optimal than cases no conxol, normal tool and another cases
4.3.2 Comparison PP value of displacement
Figure 4.12: The chart of peak to peak values of displacement on axial axis12
Case 23 of cases which have conxol structure has the lowest peak to peak value of displacement on axial axis
Figure 4.13: The chart of peak to peak values of displacement on radial axis13
Case 9 of cases which have conxol structure has the lowest peak to peak value of displacement on radial axis
Figure 4.14: The char of peak to peak values of displacement on horizontal axis14
Case 16 of cases which have conxol structure has the lowest peak to peak value of displacement on horizontal axis
Conclusion: Cases conxol 23, 9 and 16 have PP value of displacement are more optimal than cases no conxol, normal tool and another cases
The experimental results indicate that acceleration and displacement are ineffective in optimizing parameters for precise damping, ultimately leading to time and cost inefficiencies in the survey process Furthermore, this mechanism does not contribute to enhancing surface roughness in high-gloss workpieces.
CONCLUSION AND FURTHER RESEARCH DIRECTION
Conclusion
After conducting research, the issue was followed by manufacturing, testing, and cutting process observation The following are the project's results:
- Know the factors that influence how vibration arises during machining
- The impact of vibration on the surface's quality after being machined
- The effect of the machined surface on the workability of the component Design and manufacture the damper handle
- To acquire results while conserving time and money, create effective techniques for using it, select the proper set of parameters for survey studies, and do tests
- Compare the surface roughness of the surfaces produced by milling with a normal cutter handle and a damper handle in a table
To enhance surface gloss during component processing, it is essential to implement specific technological measures and optimal cutting equipment settings The project objectives were achieved through testing various samples under controlled experimental conditions, leading to the development of the damper handle and identification of its applications Utilizing damping cutter handles allows for improved surface quality across different materials and milling settings, making this method versatile for various processing needs.
The following specific goods have been produced as a result of the project's implementation process:
- Table of results for conxol instances with varied machined surface roughness
- Ability to increase the quality of the machined surface on conxol models
- Table of results of the ability to absorb vibration of the toolholder during machining of conxol models.
Further research direction
To achieve the finest surface polish, it is crucial to consider the tool's cutting direction and route Additionally, an evaluation of different materials such as aluminum and steel is essential Further research is needed on the dampening system of the cutting handle to enhance performance.
[1] Nguyễn Ngọc Đào, Trần Thế San, Hồ Viết Bình, Chế độ cắt gia công cơ khí, NXB Đà Nẵng, 2002
[2] Clarence W de Silva, Vibration Damping, Control, and Design, April 5, 2007
[3] Application of Taguchi method in optimization of end milling parameters by J.A Ghani, I.A Choudhury, H.H Hassan – University Malaysia
[4] Study on the effect of cutting mode on surface roughness when machining on CNC milling machines by Truong Thi Ngoc Thu - University of Da Nang
This experimental study by Ngo Duc Hanh from Thai Nguyen University investigates the properties of self-excited vibrations in metal cutting processes It emphasizes the significant impact of feed rate on the growth of these vibrations, utilizing advanced computational methods to analyze the findings The research provides valuable insights into optimizing cutting conditions to enhance machining efficiency and product quality.
[6] Research to improve the surface quality of machine parts when finishing milling, Hoang Trong Hieu - University of Da Nang
[7] Nguyễn Ngọc Đào, Hồ Viết Bình, Phan Minh Thanh, Cơ sở công nghệ chế tạo máy, NXB Đại học quốc gia TP.HCM, 2004
[8] Hồ Viết Bình, Công nghệ chế tạo máy, NXB Đại học quốc gia TP.HCM, 2008
[9] https://haasvn.com/dao-phay-la-gi/
[10] ThS Trần Quốc Hùng, Giáo trình dung sai kỹ thuật đo, NXB Đại học quốc gia TP.HCM, 2012
[11] Geometrical Product Specifitions (GPS) – Indication of surface texture in technical product documentation, International standard ISO 1302 – 2002
[12] https://www.sandvik.coromant.com/pt-pt/tools/tooling-systems/turning-centres- and-lathes/silent-tools/application-guide-silent-tools/milling-appl-guide
[13] https://www.casmansuministros.com/blog/fresado-vibracion
[14] https://chainheadway.com/latest-news/negative-rake-inserts/
[15] TaguchiG., Chowdhury S., Wu Y., Taguchi’s Quality Engineering Handbook, John Wiley&Sons, 2005, NJ
[16] Huu Loc Nguyen, Taguchi Method (Phương pháp Taguchi)
[17] Hanwen Jiang and Liang Gao, Optimizing the Rail Profile for High-Speed Railways Based on Artificial Neural Network and Genetic Algorithm Coupled Method
[18] Nghiêm Hùng, Sách tra cứu thép gang thông dụng, Đại học bách khoa Hà Nội, 1997
[20] The Peak, Peak to Peak and RMS values in vibration analysis (dynamox.net)
The graduation thesis project titled "The Blueprint" is a collaborative effort by students Tran Cao Long, Nguyen Anh Tu, and Nguyen Dinh Hieu from the Faculty of Machine Engineering at HCMC University of Technology and Education Under the guidance of advisor M.E Le Ba Tan, the project was conducted during the 2022-2023 academic term.
B ol t 1 4 Co m pl ia nt 1 3 B us hi ng 1 2 Cu tt in g to ol 1 1 D ES CR IP TI O N P A R T N U M B ER Q TY IT EM Designer ApproverA ss em bl y Scale : 1 : 1 Quantity: 1
H CM C U ni ve rs it y of T ec hn ol og y & E du ca ti on F ac ul ty C la ss
The HCMC University of Technology and Education's Faculty of Design has approved a cutting tool for use in their classes, specifically a ductile iron scale at a ratio of 1:1, model number 133 M466 160.
The Designer Approver for the HCMC University of Technology and Education has specified a class steel scale ratio of 3:1 for the sheet.
Te ch ni ca l re qu ir em en t: - Ch am fe r 0 5x 4 5 - To le ra nc e 0 2
The Designer Approver mounting tool at HCMC University of Technology and Education features a class steel scale of 2:1 and is constructed from sheet material measuring 116.
2 Te ch ni ca l re qu ir em en t: - To le ra nc e 0 2
Designer ApproverCo m pl ia nt 1 S te el
H C M C U n iv er si ty o f Te ch no lo g y & E d uc at io n F ac ul ty C la ss
R z5 0 Te ch ni ca l re qu ir em en ts : - Cy lin dr ic it y