Đồ án fabrication of damping models using magnetic fluids (ferrofluids) application for turning tool

OVERVIEW

Reasons for choosing a topic

The mechanical sector has experienced exponential technological growth since ancient times, playing a crucial role in the economic and social development of countries Fundamental knowledge in mathematics, physics, chemistry, and engineering principles is essential for mechanical engineering, which focuses on creating machines and equipment for various human activities Key machinery, such as lathe machines, milling machines, and CNC machines, has been developed to enhance production processes in mechanical factories In Vietnam, a developing country, foreign investments have established production lines for bicycles, auto parts, and motorcycles, where lathe machines are used to manufacture detailed spare parts However, producing these components through traditional methods requires significant time and effort.

Damping during turning processes significantly enhances detail precision This study explores the deflagration effects of ferrofluid media, aiming to identify innovative advantages over traditional deflagration methods By utilizing magnetic liquid ferrofluid in conjunction with a permanent magnet, we address the challenges associated with this phenomenon Ferrofluid's high fluid mobility makes it highly responsive to external forces, allowing it to function effectively as a dispersing agent within absorbers Its movement within the absorber, influenced by fluctuating inertial forces, contributes to the efficient dispersion of fluctuating energy.

This research is essential for enhancing our understanding of how comfort vibrations affect processing, as well as for exploring the practical applications of this method By doing so, we can identify ways to implement these findings in processing to meet industry standards.

So, this topic is a need for a better understanding of the different aspects of impact, so the process is convenient but not clear

Starting from such a need, we choose the topic: “Fabrication of damping models using ferrofluids application for turning tool”.

Research results in Viet Nam and the world

In mechanical processing, understanding the factors that influence machining quality—such as technological systems, external components, materials, and cooling—is crucial for metal cutting technology This need has intensified with the emergence of advanced tools, cutting machines, and processing materials Among the various aspects of machining quality, achieving surface gloss is particularly significant However, in deep hole turning, attaining a high gloss finish poses challenges due to the fixed position of the tool, which reduces stiffness and increases vibration, ultimately impacting the roughness of the machined surface.

Recent studies have extensively examined how cutting methods, parameters, and technology systems affect surface roughness in both universal and CNC machining However, there is limited research on the impact of damping tool shanks—a novel cutting technology—on the surface gloss of machined components, particularly since this technology has not yet gained widespread adoption in Vietnam.

2 necessary to investigate it because the surface gloss of mechanical parts is very demanding, so damping technology is increasingly used in machining

Some of the latest research on damping turning tool were conducted in Japan In a

A 2019 study demonstrated that employing a damper shank during the cutting process significantly reduces cutter force and enhances the durability of the cutter, as measured by researchers using a dynamometer.

This study has made important conclusions about optimization of the cutting process

Recent studies in the US and Europe have focused on the impact of damper shanks in cutting machining Research conducted by European scientists indicates that damping tool holders can effectively reduce vibrations and enhance processing speed, leading to improved production efficiency.

In these studies, The scientists mainly focused on the use of new materials and improved design solutions to minimize the vibration of the the tool

A team of researchers from the University of Stuttgart, Germany, conducted a study published in the Proceedings of the 2017 International Conference on Vibration Engineering and Control They investigated a three-layered shock-absorbing system, comprising a rubber sleeve, a metal spring, and a plastic insert, to assess its effectiveness in reducing vibrations and shocks Field tests with various power tools demonstrated that this innovative system could reduce vibrations and shocks by up to 70% The researchers concluded that the shock-absorbing system could significantly help in minimizing fatigue and injury among workers using power tools.

Researchers from the University of Lorraine in France have demonstrated that using plastic compliant dampers in turning operations can significantly enhance performance Their study revealed a reduction in peak surface roughness by up to 48% and an increase in tool life by 50% This improvement is attributed to the dampers' ability to mitigate vibrations and shocks during the turning process, which can lead to tool chatter, poor surface finish, and premature wear Implementing plastic compliant dampers is a cost-effective and straightforward solution that not only enhances surface quality and tool longevity but also boosts overall productivity in turning operations.

Purpose of the topic

- An overview study on damping technology in metalworking and cutting

This article explores the fabrication and experimentation of a turning tool featuring an integrated damping system and magnetic field, focusing on its impact on surface gloss when varying the internal parameters of the damper shank on CT38 steel in Vietnam The study also includes a comparison with a standard turning tool to evaluate performance differences.

- Make comments on which parameters optimize the surface quality when using the damper shank with integrated damping system inside the turning tool core

Perform of the topic and the limitations of the topic

Starting from the title of the topic and the above purpose, the research direction includes the following tasks:

When evaluating metal cutting, it's essential to consider the theoretical framework of the process, the quality of the surface produced post-machining, and the various factors that influence the quality of the machined surface.

Research on vibration in the machining process focuses on understanding its causes, examining how it affects machining quality, and proposing effective solutions to minimize vibration By identifying the sources of vibration, this study aims to enhance machining precision and overall productivity, ultimately leading to improved product quality and reduced operational disruptions Implementing recommended strategies can significantly mitigate vibration-related issues in machining operations.

- Design and manufacture of turning tool holders with integrated damping system

• Prepare the workpiece, 2 types of shank (normal shank and consol damper shank) and insert piece for each shank

To effectively measure and assess vibration in various turning tools, it is essential to prepare machines, handles, and sensors This includes evaluating the normal turning tool shank, the damper shank without a console, and the damper shank with an inner console across three mediums: air, water, and vegetable oil.

• Prepare machines, knives and test cutters to test the technology system, check the stability of the jigs

This study involves conducting cutting tests on a specific material using a turning tool handle, while systematically varying the damping system Key modifications include adjusting the distance between the magnet and the handle, as well as altering the percentage of iron powder within the ferrofluid These changes aim to assess their impact on the tool's performance and efficiency during the cutting process.

- Process data, chart and compare, analyze, and evaluate results

1.4.2 The limitations of the topic

Due to limitations in terms of time and equipment, the scope of the study is as follows:

- Samples were cut on a milling machine in the Vietnamese workshop of Ho Chi Minh City University of Technology

- The test was conducted on only one type of boring tool shank S20R- MTJNR16

- Using an insert fragment type: TNMG160404 R04

- Only conduct the test on CT38 steel material

This study investigates the impact of varying design parameters of the consol and ferrofluid within the damper shank on the surface gloss of the part, while maintaining consistent cutting parameters (𝐹 𝑧, 𝑉 𝑐, t) as specified by the manufacturer.

Research methods

- Turning and measuring roughness on CT38 steel material surface

- Experiment on lathe in Viet Duc workshop of Ho Chi Minh City University of Technology

- Measure surface gloss with Mitutoyo SJ-201 handheld roughness meter

- Tabulate the results and draw a roughness comparison chart between a surface milled with a normal shank and a damper shank when turning in the same cutting mode

THEORETICAL BASIC

The concept of turning machining methods

Turning machining is a widely used cutting method that utilizes the rotational motion of the workpiece combined with the tool's longitudinal and transverse feed movements In machining workshops, lathes represent approximately 25% to 35% of the total equipment, highlighting their significance in manufacturing processes.

Commonly used for turning operations, various types of lathes include universal screw thread lathes, vertical lathes, truncated lathes, RW lathes, automatic lathes, and CNC lathes Additionally, other machines such as drills, milling machines, and boring machines are capable of performing similar tasks.

When turning turning, the basic movement mainly includes the following movements:

The rotation of a machined part on a lathe is driven by the spindle, enabling the part to spin and allowing the cutting tool to maneuver around it This process is essential for achieving the desired shape and size of the component.

The X-axis forward motion refers to the horizontal movement along the main axis of the lathe, determining the speed at which the cutting tool traverses the surface of the workpiece.

The Z axis forward motion refers to the movement along the Z axis, parallel to the lathe's main axis This motion determines the speed at which the cutting tool vertically traverses the part's surface.

The interaction of movements during turning plays a crucial role in determining the cutting tool's trajectory on the part surface Effectively controlling and adjusting these movements is essential for achieving high-quality machining, ensuring desired accuracy, and meeting specific part specifications.

A turning tool is specifically designed for cutting during the turning process, and it comes in various types, including straight end, curved end, shoulder, face, hole, and profile tools Additionally, there are specialized tools for outer and hole pieces, threaded turning, and slotting, each serving unique functions in machining.

Some of the characteristics of turning machining methods include:

- While turning uses the circular motion of the tool and the workpiece at rest, turning uses the reciprocating motion of the cutting edge

- The basic V cutting speed depends on the strength of the workpiece, the cutting piece and the resistance to heat and abrasion

In machining, the feed rate, denoted as "f," refers to the distance the cutter advances in one revolution of the workpiece Rough turning typically employs larger feeds for efficient material removal, whereas fine turning utilizes smaller feeds for precision finishing The depth of cut is influenced by the feed movement, allowing for effective control over the machining process.

- Parts with round shapes such as smooth shafts, tapered shafts, hole and eccentrics are mainly produced by turning machining

- The turning tool usually has a replaceable handle and cutting piece Different types of turning often require a compatible tool

Lathes offer superior accuracy in machining parts and products compared to other methods, though the final precision can vary based on several factors.

Machine accuracy is determined by evaluating spindle oscillation and the parallelism between the slide and spindle center Additionally, the accuracy is influenced by the coaxial alignment of the motors and spindles within the lathe.

- Condition of the cutting tool

- Coaxially between the inside and the outside of the product.

Problems affecting damping in turning method

There are a number of issues that affect the damping ability of a lathe The following is a list of factors that can cause unwanted damping during machining on a lathe:

- Machine Vibration: If the lathe is unstable or not well balanced, it can generate vibrations during machining, leading to unwanted damping and affecting product accuracy

Cutting tool vibration in lathe machining can significantly impact quality When cutting tools are not securely fastened or properly honed, they can generate unwanted vibrations during material contact Ensuring proper tool attachment and maintenance is essential for achieving optimal machining results.

- Incorrect adjustment: If the lathe components are not adjusted properly, for example the spindle is not aligned or the components are not tightened properly, it can cause unwanted vibrations

Overloading a lathe by exceeding its load capacity can lead to undesirable vibrations This issue often arises when machining materials that are excessively hard or heavy for the machine.

The hardness of a workpiece significantly influences the damping ability of a lathe Harder materials generate greater machining forces that are more challenging to control, leading to undesirable damping effects during the machining process.

These issues need to be addressed to ensure good damping and high machining quality on the lathe.

Damping methods for turning method

There are several common damping methods used on lathes to reduce vibrations and increase machining accuracy Here are some commonly used methods:

Incorporating a damper into your lathe can significantly enhance machining precision by minimizing vibrations Many lathes feature advanced damping systems, including cone dampers, spring dampers, and hydraulic shock absorbers, designed to effectively absorb and reduce vibrations during the machining process.

Optimizing cutting speed is crucial for minimizing vibration during machining processes By carefully adjusting the cutting speed to match the material type and part dimensions, manufacturers can effectively prevent unwanted vibrations, leading to improved precision and surface finish.

Using high-quality cutting tools is essential for minimizing vibrations and enhancing machining accuracy on lathes Tools that are well-designed and possess the appropriate rigidity significantly improve performance and the overall quality of the machining process.

- Adjusting machining parameters: Adjusting machining parameters such as federate, depth of cut, and amount of lubrication can help reduce vibrations

Depending on the material and part size, these parameters can be adjusted to optimize the machining process and reduce vibration

Automatic control systems in lathes enable real-time monitoring and adjustment of machining parameters, enhancing accuracy and reducing vibration through automatic detection and correction.

However, the specific damping method should be considered on a case-by-case basis and under specific machining conditions A method or a combination of methods.

The concept of magnetic fluid (Ferrofluid)

Ferrofluids are unique fluids composed of a blend of active magnetic particles and a neutral magnetic liquid They are created by dispersing tiny magnetic particles, typically iron or iron compounds, into a mesomagnetic medium like oil or water.

Creeping fluids, particularly ferrofluids, exhibit a unique ability to respond and alter their shape when exposed to an external magnetic field Upon the application of this magnetic field, the magnetic particles within ferrofluids align and form distinct structures such as beads, threads, or columns throughout the liquid This interaction not only induces a creeping motion but also modifies the viscosity and overall shape of the fluid, showcasing the fascinating behavior of ferrofluids in response to magnetic stimuli.

Ferromagnetic fluids have a wide range of applications across various fields, including information technology for computers and data storage, medicine for cancer treatment and imaging, robotics for robot control, and electronics for sensors and magnetic controllers.

Magnetic fluids, particularly Ferrofluids, provide substantial advantages for developing applications and devices that can be remotely adjusted and controlled Their unique properties have garnered considerable attention and research from both scientific and industrial sectors, highlighting their versatility and potential for innovative uses.

Application of magnetic fluid

Ferrofluids are versatile materials with numerous applications across various fields, particularly in technology and electronics They play a crucial role in magnetic sensors and filters, enhancing device performance by regulating current, minimizing noise, and boosting sensitivity Additionally, ferrofluids are employed in the cooling of electronic components, including LEDs and microchips, ensuring optimal functionality and longevity.

Ferrofluids play a significant role in the medical field, particularly in enhancing diagnostic and treatment processes They are utilized in magnetic resonance imaging (MRI) to generate detailed internal images of the body, aiding in accurate assessments Additionally, ferrofluids hold promise for advancing cancer diagnosis by offering precise images of magnetic-substance interactions.

Ferrofluids have emerged as a groundbreaking medium in art and design, enabling the creation of captivating visual effects such as magnetic highlights, motion dynamics, and distortion These versatile fluids are increasingly utilized in unique artworks, promotional items, and innovative product designs, showcasing their potential to transform creative expression.

Ferrofluids play a crucial role in scientific research by enabling the study of magnetic phenomena and the interactions of magnetic particles in liquids Additionally, they are utilized in robotics and automation to develop flexible, magnetically controlled devices, allowing for the creation of soft and adaptable moving components in robotic systems.

Surface roughness

Surface roughness is a crucial characteristic for assessing surface properties, reflecting the texture and irregularities perceived through touch or sight It is quantitatively measured using specific parameters, providing an accurate and objective evaluation of the surface's condition.

Common quantitative parameters used to describe surface roughness include:

Roughness Average (R_a) is a key parameter that quantifies surface deviations from a baseline, reflecting the average depth of irregularities across a surface It effectively measures the differences in elevation between various points, providing insight into the overall texture and settlement characteristics of the material.

Mean Roughness Depth (Rz) quantifies the maximum vertical distance between the highest and lowest points on a surface, reflecting the depth of its grooves and peaks This parameter is essential for assessing surface texture and quality.

Total Roughness (R_t) quantifies the vertical distance between the highest and lowest points on a surface, representing the cumulative absolute deviations from the average surface level.

The parameter R max, or Maximum Height of Profile, quantifies the maximum distance between the highest and lowest points on a surface, reflecting the overall magnitude of surface irregularities.

𝑅 𝑎 and 𝑅 𝑍 measured in common surface roughness measurement units such as microns (μm) or microinches (μin)

Surface roughness plays a crucial role across various industries, including machine building, technology, medicine, and electronics It significantly influences surface properties, impacting factors like coupling, heat transfer, mechanical performance, material interactions, and overall aesthetics.

In turning machining, surface roughness is crucial for evaluating the quality and precision of the workpiece Proper measurement and control of surface roughness ensure that the surface meets specifications and is suitable for its intended application.

To achieve the desired surface roughness in turning machining, it is essential to implement effective damping methods, which include utilizing damping systems, adjusting machining parameters, and selecting high-quality cutting tools These strategies play a crucial role in enhancing surface quality during the turning process.

10 measured with roughness measuring devices such as surface roughness tester to ensure desired surface quality is achieved and customer specifications are met machining details

Vibration and damping in mechanical processing

Vibration in mechanical machining refers to unwanted and irregular oscillations that occur during the machining of mechanical parts This phenomenon can lead to issues such as imbalances, heightened vibrations, reduced precision, damage to cutting tools, and a shortened lifespan of machine components.

There are many types of vibrations that can occur during mechanical machining, and they can have different causes Here are some common types of vibrations and their causes:

- Chatter: This type of vibration causes unwanted and irregular oscillations during cutting Causes may include:

• The machine structure is not rigid or stable

• Active tools are not balanced or incorrect

• Cutting speed is too fast or uneven

• Inappropriate or damaged cutting tool design

- Vibration: This is the combined vibration of the uneven and unbalanced elements in the machining process Causes may include:

• Uneven or unstable cutting speed

• Unbalanced or incorrect cutting tools

• The shear force and the compensation force are not balanced

• The structure is subject to vibration during machining

- Self-Excited Vibration: This type of vibration is spontaneous and self-sustaining during machining Causes may include:

• The structure of the machining machine and the cutting tool has creep properties

• Unstable or inappropriate contact point between the cutting tool and the work piece

• The cut-off rate is close to the region of the natural frequency of the system

- System Vibration: This type of vibration is caused by interactions between the components of the machining system Causes may include:

• Improper balance and coupling between components

• The damping system is ineffective or not working properly

In addition, the causes of vibration in mechanical processing can be:

Imbalances in machined components or cutting tools can cause vibrations, often resulting from improper installation and calibration of the machining equipment.

Suboptimal design of machines and cutting tools can lead to vibrations, primarily due to insufficient stiffness and balance These vibrations arise from the unstable characteristics inherent in the equipment, negatively impacting performance and efficiency.

Using an incorrect or unstable cutting speed can lead to vibrations during machining When cutting speeds are excessively high, they generate significant force and torque, resulting in unwanted vibrations that can affect the quality of the workpiece.

- Improper vibration barrier: Lack of vibration barrier or suboptimal design can lead to vibration during machining The lack of damping or vibration control systems can also increase vibrations

Vibration during mechanical machining can negatively impact product quality, accelerate tool wear, extend machining times, and decrease overall productivity To mitigate these effects, it is essential to implement damping measures, which include utilizing damping systems, adjusting machining parameters, selecting high-quality cutting tools, and optimizing the machine structure.

Damping is essential in machining as it effectively reduces unwanted vibrations and oscillations, leading to enhanced product quality and extended tool life By improving machining efficiency and minimizing energy consumption and wear, damping plays a crucial role in optimizing manufacturing processes.

There are many common damping methods applied in machining methods, including:

Incorporating damping systems in turning and machining machines is essential for reducing vibrations These systems, which can include cone dampers, spring dampers, hydraulic dampers, or air dampers, effectively absorb vibrations, enhancing the overall performance and precision of the machinery.

Optimizing machining parameters, including cutting speed, depth of cut, and lubrication, is essential for minimizing vibrations during the machining process Properly selecting these parameters not only stabilizes machining operations but also significantly reduces the occurrence of vibrations.

Utilizing high-quality cutting tools with optimal design and appropriate rigidity significantly minimizes vibrations and enhances machining accuracy Additionally, the geometry and shape of the cutting tool play a crucial role in its damping capabilities.

- Using automatic control system: Some machining machines are equipped with automatic control system to monitor and adjust machining parameters in real time

This system can detect and adjust automatically to reduce vibration and ensure accuracy

- Optimizing the machine structure: The design and structure of the machine can be optimized to reduce vibrations and increase rigidity and stability

2.7.3 Damping during cutting by Console system

The damper console beam plays a crucial role in damping systems designed to minimize vibrations and oscillations in various engineering applications Frequently utilized in industrial and mechanical settings, this component effectively mitigates the impact of vibrations on structures and systems, enhancing overall stability and performance.

Damping console girders are usually made of flexible and damping materials It has the ability to absorb and dampen vibrational energy, thereby reducing unwanted vibrations and oscillations

Applications of damper console beams include:

- Damping vibrations in machinery and equipment systems

- Damping vibration and noise in piping and ducting systems

- Damping vibrations in structures and structures such as bridges, buildings, and industrial equipment

- Vibration damping in automotive and aeronautical applications

- Damping console girders can be designed and customized to meet the specific requirements of each application, including dimensions, materials, and damping properties.

Sensor for measuring the vibration of the tool in cutting machining

TcAs (Thermocouples with Accelerometers) are advanced sensors that integrate both thermocouples and accelerometers, enabling the simultaneous measurement and monitoring of vibration and temperature These sensors are specifically designed for use in industrial applications and harsh environments, providing reliable data for optimal performance and safety.

A thermocouple sensor is an essential device for measuring temperature, operating on the Seebeck effect This phenomenon occurs when two different conductive materials are joined, generating an electric potential due to a temperature difference at their ends By monitoring the changes in this potential, the thermocouple sensor effectively provides accurate temperature readings in various environments.

An accelerometer is a device designed to measure vibrations by detecting variations in acceleration at its location It plays a crucial role in identifying and quantifying unwanted vibrations and oscillations in various systems and equipment.

The TcAs sensors integrate a heating sensor and an accelerometer, enabling simultaneous measurement and monitoring of temperature and vibration This dual functionality allows users to analyze the interplay between temperature and vibration in various processes and systems TcAs sensors find extensive applications across multiple fields, including industrial monitoring, engine and machinery assessment, seismic monitoring, and aerospace vibration measurement By facilitating real-time data collection, these sensors enhance understanding and improve performance in diverse environments.

13 temperature and vibration information, Sensors vibration and temperature TcAs improves process control

Sensors vibration and temperature TcAs have several important features and advantages:

- Precise Measurement: Sensors vibration and temperature TcAs use high quality accelerometer and heating sensors, allowing for precise measurement of temperature and vibration in harsh environments

This versatile instrument offers simultaneous insights into temperature and vibration, enabling users to effectively analyze the relationship between these two parameters and assess how vibration influences temperature and vice versa.

Continuous monitoring through vibration and temperature sensors, such as TcAs, allows for real-time tracking of changes in these parameters This technology facilitates early problem detection, enables accurate status assessment, and supports prompt remedial actions.

- High Durability: The device is designed to operate in harsh environments, capable of withstanding vibration, shock and high temperatures This ensures the stability and reliability of the measurement data

The TcAs vibration and temperature sensors offer exceptional ease of use, allowing for straightforward installation and operation These versatile sensors can seamlessly integrate into existing monitoring systems or function effectively as stand-alone measuring devices.

This device enables seamless data integration from heating and accelerometer sensors, empowering users to effectively monitor and analyze measurement data from both parameters This capability supports informed decision-making and enhances performance improvement strategies.

Vibration and temperature sensors, known as TcAs, are essential for monitoring critical industrial applications They provide simultaneous data on temperature and vibration, enhancing system performance and safety while reducing the likelihood of failures.

2.8.3 Some new concepts about measured sensor parameters

Sensor’s vibration and temperature TcAs are capable of measuring and providing information about the following parameters:

The Peak-to-Peak (PP) value is a crucial indicator that measures the range between the minimum and maximum amplitudes of a signal While an increase in Peak-to-Peak amplitude may suggest the presence of certain effects, it does not convey information about the energy contained in the vibration signal, focusing solely on the highest and lowest values.

Root Mean Square (RMS) is a crucial metric for assessing the effective value of a signal, particularly in measuring the vibrational energy of a device Unlike peak values that only consider maximum amplitudes, RMS provides a comprehensive representation of the average energy within a signal It calculates this average by taking the square root of the sum of the squares of the sample values, dividing by the number of samples, and then taking the square root of that result This method ensures a more accurate reflection of the total signal energy, making RMS an essential tool in vibration analysis.

Furthermore, RMS is a measure of the vibration energy of the device [4]

- KURT (Kurtosis): also known as skew, Kurtosis in a vibration signal can be graphically interpreted by considering the distribution of signal values, as shown in the following figure [5]

- CF (Skewness) distortion or asymmetry of a signal, and it can also be interpreted graphically by considering the shape of the signal distribution [5]

The RMS (Root Mean Square) value is a crucial metric that reflects the total energy of a signal, unlike Peak and Peak to Peak values, which are point values As faults develop in a monitored asset, the RMS value fluctuates due to an increase in the number of peaks, impacting the overall signal energy Initially, during the early stages of mechanical failures, the RMS value shows only minor changes, indicating minimal shifts in total signal energy However, as faults escalate, the RMS value tends to rise significantly Fortunately, most vibration analysis software automatically calculates the RMS value, enabling users to easily assess and interpret the condition of their machinery.

Kurtosis represents the degree of similarity between the values of a signal Therefore, in the case of a signal with many independent peaks or effects, the kurtosis value will be higher

MODEL DESIGN OF COVENIENT FLUID HANDLING

Technical requirements for Jigs body for magnet design

- The design must withstand the load of the attached magnet

- The design must avoid positions that obstruct the working table

- The design must withstand the extremely large attraction of the magnet

- Design to avoid damage to the table

The design calculation process is divided into 4 big steps:

1 Measuring and surveying the machine table to select parameters to conduct the design

2 Design 3D Jigs body for magnet

3 Selection of materials for crafting

4 Stress test for Jigs body for magnet

3.2 Survey of actual measurements of the machine table

The design measurement process in mechanical engineering is crucial for ensuring the reliability and accuracy of mechanical systems It encompasses several key steps, including measuring component dimensions and tolerances, verifying material properties, and testing the mechanical characteristics of the system Initially, precise measuring tools, such as millimeters and specialized rulers, are utilized to accurately determine the length, width, height, and other essential dimensions of various components.

16 components Tolerances are also defined, defines the allowable variation in the size of the components

After establishing dimensions and tolerances, it's essential to verify the material properties of the components This verification process includes testing for strength, hardness, and other mechanical properties using specialized equipment like tensile testers, hardness testing machines, and impact testing machines The outcomes of these tests ensure that the components are constructed from the appropriate materials and will perform reliably under different mechanical stresses.

The mechanical properties of the entire system are rigorously tested to confirm compliance with design specifications Specialized equipment, including load cells, strain gauges, and accelerometers, is employed to accurately measure forces, stresses, and vibrations during operation The test results validate the system's performance and guide any necessary adjustments or modifications to enhance overall efficiency.

The design measurement process in mechanics is crucial for ensuring the reliability and accuracy of mechanical systems This process includes measuring component dimensions and tolerances, verifying material properties, and testing the overall mechanical properties of the system By adhering to these steps, engineers can create safe and efficient mechanical systems that fulfill the requirements of their intended applications.

3.3 Design Jigs body for magnet

- The jig body is assembled from 5 parts together to facilitate installation and processing

- After processing and cutting 5 parts, they will be welded together

- M10x1.5 hole is used to install magnets as well as mount on the table for more convenient work

- It takes a long time to make

3.3.2 Detailed drawings and 3D models of the part

Figure 3.8: Drawing of bottom plate 6

Figure 3.14: 3D model of bottom plate 6

3.4 Selection of materials for crafting

When designing jigs, it's essential to consider the materials used for jigsaw processing Key factors include determining the specific suction force needed for the magnet on the mounting bracket, as well as evaluating mechanical strength, thermal conductivity, electrical properties, and resistance to corrosion and wear These requirements can vary based on the application.

23 the intended application, environmental conditions and operational needs Ensure that the selected materials are compatible with the intended treatment method

Assess the expenses associated with materials, encompassing raw material costs, processing fees, and any waste generated Take into account long-term considerations such as the material's durability, maintenance needs, and potential for reuse or recycling Aim to achieve an optimal balance between the performance of the material and its cost-effectiveness.

Assess the availability and accessibility of selected documents within the desired timeframe Consider factors such as delivery time, supplier reliability, and future scalability

In conclusion, selecting the appropriate process material necessitates a thorough evaluation of performance needs, material characteristics, compatibility with treatment methods, cost efficiency, supply chain factors, environmental impact, and adherence to regulations By taking these elements into account, one can make informed decisions.

From the factors of demand and price considerations, we determine the American standard AISI 1050 code material as the mounting material

AISI 1050 steel, known for its moderate carbon content and outstanding mechanical properties, offers a reliable and cost-effective solution across various industries Its exceptional strength, hardness, and wear resistance make it the preferred choice for applications demanding durability and reliability From automotive to machinery, construction, and general engineering, AISI 1050 steel consistently demonstrates its versatility and dependability.

In [7], we have chemical composition of AISI 1050 steel:

Table 3.1: Chemical composition of AISI 1050 steel

According to [8], we have physical properties:

(MPa) flow limit (MPa) elongation rate (%)

AISI 1050 steel exhibits mechanical properties that provide strength, toughness, and resistance to deformation, making it ideal for applications in the mechanical and automotive industries Common uses include the production of gears, shafts, and springs Additionally, its affordable purchasing and processing costs align well with magnet manufacturing, effectively meeting industry demands.

3.5 Stress test for Jigs body for magnet

3.5.1 Meshing the magnet jig pattern

The order of execution consists of the following steps:

- Import existing jigsaw models into the Ansys environment by exporting the model to extensions that the Ansys software accepts

- Edit Engineering Data – enter the necessary specifications about the material of the fixture

- Enter the Ansys analysis environment

- Mesh – meshes the model into discrete elements

- Set the necessary conditions for the fixture

- To provide the closest possible result, the computer system will perform calculations with multiple loops and consider the convergence of the results after each loop

- With the results obtained, we will analyse the data and evaluate the results against the results

Select the stress scheduling parameter for the fixture in ANSYS:

To achieve accurate results in static simulations, it is essential to use a well-structured global grid mesh, as poor mesh quality can lead to inaccuracies and extended computation times Handling static and nonlinear problems demands significant computational resources, and subpar mesh quality complicates simulations, resulting in longer processing durations Enhancing mesh quality is particularly beneficial for nonlinear problems, as it can significantly improve simulation time and facilitate easier convergence.

On the contrary, it may be difficult to converge because the mesh quality is not good

After choosing the appropriate material for the pipe, the next step is to effectively model the problem in ANSYS It is essential to simplify the problem to ensure that it is not overly complicated when inputting it into the software.

To improve, we should simulate the main details while keeping the working

- With the requirement of the problem is meshing jigs for three-piece magnets to simulate to save time, simplify the problem while keeping the required accuracy of the problem

Figure 3.15: Fixtures in the Ansys environment

The fixture is designed with the main function of being directly attached to the workbench and can withstand a sustained suction from the magnet for a long time without much deformation

Figure 3.16: Lower clamp plate in Ansys environment

The lower clamping plate is essential for securely fastening the jig to the table using M10 threaded holes, enabling it to support substantial loads from jigs and magnets It effectively counteracts the magnetic attraction exerted on the turning tool handle, ensuring stability during operation.

Figure 3.17: Fully complete model in Ansys environment

From the 3-D model, divide the original model into 3 different elements and the meshing is also different depending on the element that we want to analyse more closely or not

To optimize the problem to achieve the most accurate results as well as to save the most simulation time, we must think carefully before choosing the meshing method

Once the problem model is meshed, the surface of the detailed panels exhibits a smooth mesh However, near the hole of the lower clamp, various geometries are observed.

Thus, with the above meshing method, we can completely simulate the deformations and stresses depending on the requirements

3.5.2 Stress and deformation analysis of the fixture

The steps are simulated and performed by Ansys:

1 Select Static Structural to create the element

3 Select Engineering data to enter material data

1 Change the unit from Pa to MPa

2 Input the AISI 1050 material data

3 Select Browse to add a spt 3D file for simulation

Figure 3.22: Simulate Ansys 4 Describe: Select Model to open analysis

1 Right click on the mesh

3 Select sizing for meshing options

1 Select the geometry in the lower corner panel to customize the face

2 Select any plane on the 3D model then press ctrl + A to scan the entire face, then press apply in the geometry panel

3 Select the element size parameter for meshing (5mm)

2 Click Generate Mesh to calculate meshing

Figure 3.26: Simulate Ansys 8 Describe: After meshing we get about 27750 elements

1 Select Static Structural to open the force environment

4 Click Apply to complete Fixed

2 Select the face where the force is applied

3 Click Apply to complete face selection

4 Enter the number to complete the force setting

5 In the Direction box, choose the direction of the force, then apply to complete

Figure 3.29: Simulate Ansys 11 Describe: Put a force of 30N for tightening force for 2 side M10 hex bolts

Figure 3.30: Simulate Ansys 12 Describe: Put a force of 30N for the M10 hex bolt tightening force from above

Figure 3.31: Simulate Ansys 13 Describe: Set the tightening torque to 11.85N for 4 screws

Figure 3.32: Simulate Ansys 14 Describe: Set tightening torque to 20N for 4 hex bolts M10x70mm

1 Click on Solution to open the force simulation interface

1 Right click on the Solution to open the menu

2 Click Solve to calculate the simulation

Figure 3.36: Simulate Ansys 18 Describe: Total deformation simulation results

Figure 3.37: Simulate Ansys 19 Describe: The result of stimulate Equivalent Stress

Meshing plays a crucial role in achieving accurate simulation results, as smaller element sizes lead to greater precision The magnet spacing setting does not influence the turning tool, resulting in a minimal total deformation of just 0.05567 mm This small deformation confirms that the results align with the specified conditions and guarantees the rigidity of the actual mounting frame.

Design Jigs body for magnet

- The jig body is assembled from 5 parts together to facilitate installation and processing

- After processing and cutting 5 parts, they will be welded together

- M10x1.5 hole is used to install magnets as well as mount on the table for more convenient work

- It takes a long time to make

3.3.2 Detailed drawings and 3D models of the part

Figure 3.8: Drawing of bottom plate 6

Figure 3.14: 3D model of bottom plate 6

Selection of materials for crafting

When designing jigs, it's essential to consider the materials used in jigsaw processing Key factors include determining the specific suction force needed for the magnet on the mounting bracket, as well as evaluating mechanical strength, thermal conductivity, electrical properties, and resistance to corrosion and wear These requirements will differ based on the specific application.

23 the intended application, environmental conditions and operational needs Ensure that the selected materials are compatible with the intended treatment method

When evaluating material costs, it's essential to consider not only the expenses associated with raw materials and processing but also any waste or debris generated Additionally, long-term factors such as the material's durability, maintenance needs, and potential for reuse or recycling should be taken into account Ultimately, the goal is to find a balance between material performance and cost-effectiveness.

Assess the availability and accessibility of selected documents within the desired timeframe Consider factors such as delivery time, supplier reliability, and future scalability

In conclusion, selecting the appropriate process material necessitates a thorough evaluation of performance requirements, material properties, compatibility with treatment methods, cost-effectiveness, supply chain factors, environmental impact, and regulatory compliance Taking these elements into account is essential for making an informed decision.

From the factors of demand and price considerations, we determine the American standard AISI 1050 code material as the mounting material

AISI 1050 steel, known for its moderate carbon content and outstanding mechanical properties, offers a reliable and cost-effective solution across various industries Its exceptional strength, hardness, and wear resistance make it the preferred choice for applications demanding durability and reliability From automotive to machinery, construction, and general engineering, AISI 1050 steel consistently demonstrates its versatility and dependability.

In [7], we have chemical composition of AISI 1050 steel:

Table 3.1: Chemical composition of AISI 1050 steel

(MPa) flow limit (MPa) elongation rate (%)

AISI 1050 steel is favored for its mechanical properties, offering strength, toughness, and deformation resistance, making it ideal for applications in the mechanical and automotive industries It is widely utilized in the production of gears, shafts, springs, and various components Additionally, its affordability in both purchasing and processing aligns with the cost-effectiveness of manufacturing magnets while fulfilling user requirements.

Stress test for Jigs body for magnet

3.5.1 Meshing the magnet jig pattern

The order of execution consists of the following steps:

- Import existing jigsaw models into the Ansys environment by exporting the model to extensions that the Ansys software accepts

- Edit Engineering Data – enter the necessary specifications about the material of the fixture

- Enter the Ansys analysis environment

- Mesh – meshes the model into discrete elements

- Set the necessary conditions for the fixture

- To provide the closest possible result, the computer system will perform calculations with multiple loops and consider the convergence of the results after each loop

- With the results obtained, we will analyse the data and evaluate the results against the results

Select the stress scheduling parameter for the fixture in ANSYS:

For static problems, a well-structured global mesh yields satisfactory computation time and accuracy; however, low-quality meshes can lead to less precise outcomes Addressing static and nonlinear issues demands significant computational resources, and inadequate mesh quality complicates simulations, resulting in extended computation times Enhancing mesh quality for nonlinear problems can significantly reduce simulation time and facilitate easier convergence.

On the contrary, it may be difficult to converge because the mesh quality is not good

After choosing the appropriate material for the pipe, the next step is to effectively model the problem in Ansys, ensuring that the complexity is manageable.

To improve, we should simulate the main details while keeping the working

- With the requirement of the problem is meshing jigs for three-piece magnets to simulate to save time, simplify the problem while keeping the required accuracy of the problem

Figure 3.15: Fixtures in the Ansys environment

The fixture is designed with the main function of being directly attached to the workbench and can withstand a sustained suction from the magnet for a long time without much deformation

Figure 3.16: Lower clamp plate in Ansys environment

The lower clamping plate plays a crucial role in securing the jig onto the table via M10 threaded holes, ensuring stability under heavy loads from jigs and magnets It effectively withstands the magnetic attraction force exerted on the turning tool handle.

Figure 3.17: Fully complete model in Ansys environment

From the 3-D model, divide the original model into 3 different elements and the meshing is also different depending on the element that we want to analyse more closely or not

To optimize the problem to achieve the most accurate results as well as to save the most simulation time, we must think carefully before choosing the meshing method

Once the problem model is meshed, the surface mesh of the detailed panels appears remarkably smooth, while diverse geometries are observed near the hole of the lower clamp.

Thus, with the above meshing method, we can completely simulate the deformations and stresses depending on the requirements

3.5.2 Stress and deformation analysis of the fixture

The steps are simulated and performed by Ansys:

1 Select Static Structural to create the element

3 Select Engineering data to enter material data

1 Change the unit from Pa to MPa

2 Input the AISI 1050 material data

3 Select Browse to add a spt 3D file for simulation

Figure 3.22: Simulate Ansys 4 Describe: Select Model to open analysis

1 Right click on the mesh

3 Select sizing for meshing options

1 Select the geometry in the lower corner panel to customize the face

2 Select any plane on the 3D model then press ctrl + A to scan the entire face, then press apply in the geometry panel

3 Select the element size parameter for meshing (5mm)

2 Click Generate Mesh to calculate meshing

Figure 3.26: Simulate Ansys 8 Describe: After meshing we get about 27750 elements

1 Select Static Structural to open the force environment

4 Click Apply to complete Fixed

2 Select the face where the force is applied

3 Click Apply to complete face selection

4 Enter the number to complete the force setting

5 In the Direction box, choose the direction of the force, then apply to complete

Figure 3.29: Simulate Ansys 11 Describe: Put a force of 30N for tightening force for 2 side M10 hex bolts

Figure 3.30: Simulate Ansys 12 Describe: Put a force of 30N for the M10 hex bolt tightening force from above

Figure 3.31: Simulate Ansys 13 Describe: Set the tightening torque to 11.85N for 4 screws

Figure 3.32: Simulate Ansys 14 Describe: Set tightening torque to 20N for 4 hex bolts M10x70mm

1 Click on Solution to open the force simulation interface

1 Right click on the Solution to open the menu

2 Click Solve to calculate the simulation

Figure 3.36: Simulate Ansys 18 Describe: Total deformation simulation results

Figure 3.37: Simulate Ansys 19 Describe: The result of stimulate Equivalent Stress

Meshing plays a crucial role in achieving accurate simulation results, as smaller element sizes enhance precision The magnet spacing setting does not influence the turning tool, resulting in a minimal total deformation of 0.05567 mm These findings align perfectly with the established conditions, confirming the rigidity of the actual mounting frame.

EXPERIMENTAL RESEARCH ON THE EFFECT OF SHOCKING TURNING

Experimental procedures

Set up the test procedure as follows:

According to [9], we have specifications of lathe:

4.1.1 Turning tool and Console system

- Dimesion: Use hollow cylindrical billet with outer diameter 51mm, inner diameter 31mm and the thickness of the workpiece is 25mm

CT38 steel is a versatile medium to high-strength bearing steel widely utilized in construction and mechanical applications Known for its low carbon content, CT38 offers enhanced smoothness and ease of fabrication, making it an ideal choice for various engineering projects.

In addition, it also has good wear resistance and heat resistance, which increases the service life and durability of products machined from CT38 steel

CT38 steel is extensively utilized in construction projects, including bridges and buildings, as well as in civil and industrial applications Additionally, it plays a crucial role in the production of machine parts, mechanical tools, and various other machined products.

CT38 steel is known for its high density, excellent thermal conductivity, and impressive tensile strength, which contribute to the safety and stability of constructions To maintain its shine and prevent oxidation, it is crucial to implement proper care and maintenance for CT38 steel.

Using Mitutoyo's SJ-201 roughness meter

Figure 4.5: Roughness meter Mitutoyo SJ-201

Some features of the Mitutoyo SJ-201 roughness meter:

- Large characters are displayed on the large easy-to-see LCD screen

- Portable for easy measurement wherever needed

- The detector/driver can be removed from the display unit for easy measurement of workpieces with irregular orientation

- Roughness parameters compatible with ISO, DIN, ANSI, JIS

- 19 analysis parameters are provided, including basic Ra, Rq, Rz and Ry parameters

- Evaluate GO/NG on a desired parameter

- Auto sleep function saves energy

- 10 Measurement data is retained in the memory even after the power is turned off

As in [10], we have table:

Table 4.1:Units of the Mitutoyo SJ roughness meter-201

To initiate the experiment, a vibrating device is essential, as the billet cutting method is not suitable for measuring vibration due to the lengthy duration required to obtain results.

Cases for testing

4.2.1 Shock absorbing turning tool design

To conduct the experiment, utilize a damping mechanism console that effectively transmits vibrations through a cylinder One end of the cylinder should be placed on the object to be dampened, while the other end remains free, allowing vibrations to propagate and dissipate This study necessitates the implementation of a console beam system for effective damping.

Design drawing of damper turning tool:

Figure 4.7: Design drawing of damper turning tool

Structure: The console girder is designed by 3 pieces of steel connected by plastic bars in the middle

The console girder operates with one fixed end and one free end, allowing for controlled vibration during tool holder operation As the tool holder vibrates, this motion is transmitted to the console beam, which also vibrates The connection of plastic material to the steel bars plays a crucial role, as it gradually reduces the vibration of the turning tool through its elasticity, effectively suppressing the vibrations at the free end.

Figure 4.8: Parameters of Console damper

The console girder consists of 3 segments L1, L2, L3 which are steel and 2 plastic segments with diameter A and length B

Use minitab16 software to get 25 cases summarized in the following table:

Table 4.2: Console size summary table

Figure 4.9: Face turning during console machining

After machining on the lathe, we have 25 console beams in order from left to right:

Figure 4.10: Console beams (Photo realistic)

4.2.3 Magnetic fluid concentration and magnet distance

4.2.3.1 The concentration of the fluid is variable

Ferrofluid is a unique liquid composed of metal nanoparticles suspended in a carrier liquid, granting it remarkable magnetic properties When exposed to strong magnetic fields, it exhibits super magnet behavior The ferrofluid's structure features tiny iron nanoparticles evenly distributed in an oil-based liquid, ensuring exceptional stability and retention of magnetization energy.

To achieve comprehensive and multidimensional results in this experiment, various concentrations of creeping fluid were utilized The response to the word varied significantly across five different concentrations of ferrofluid.

• Case 1: 10ml of oil mixed with 2.5grams iron powder to become ferrofluid

• Case 2: 10ml of oil mixed with 5grams iron powder to become ferrofluid

• Case 4: 10ml of oil mixed with 10grams iron powder to become ferrofluid

Figure 4.13: Magnetic fluid (no magnetic field)

Figure 4.14: Magnetic fluid (have magnetic field)

To enhance research versatility and depth, the distance between the magnet and the tool holder will be adjusted, allowing for more detailed and specific conclusions to be drawn.

With each concentration of ferromagnetic fluid, it will work with 5 different magnet distances: 3mm, 6mm, 9mm, 12mm, 15mm, respectively From there we have aggregated

25 different cases with different iron powder concentration ratio and distance

Figure 4.15: Distance between turning tool and magnet.

TcA DynaLogger

The TcAs DynaLogger is engineered to detect fault symptoms in machinery and equipment in accordance with ISO 20816 standards Equipped with a triaxial spectrometer and a contact temperature sensor, the TcA sensor effectively monitors abnormal conditions in various structures, including suspensions, pipes, and valves.

The TcAs DynaLogger offers two monitoring modes: spectra and waveform, enabling comprehensive remote monitoring across various metrics including acceleration, velocity, and displacement measured in RMS, peak, and peak-to-peak values Additionally, it tracks crest factor, skewness, kurtosis, and contact temperature In spectral monitoring, users can utilize a range of tools such as spectra, linear, circular, and orbital waveforms, along with frequency filters for enhanced analysis.

Figure 4.16: Image of the TcA DynaLogger sensor

Figure 4.17: Specifications of the TcA DynaLogger sensor

Overview of the experimental steps

Experimental steps are divided into many different steps to get the best results:

Step 1: Measure the vibration of the turning tool

In this process, the turning tool S20R-MTJNR16 will be measured without utilizing a console, magnetic fluid (Ferrofluid), or magnetic fields This includes three specific cases: Case 1 involves the default turning tool S20R-MTJNR16 (𝛼 1), Case 2 pertains to the S20R-MTJNR16 with a hole (𝛼 2), and Case 3 examines the S20R-MTJNR16 with a hole and console (𝛼 3) in an air environment.

Describe: There are 25 console cases in total, so the number of vibration measurements in Case 3 is 25 o Case 4: Turning tool S20R- MTJNR16 with hole and console in environment water

Describe: There are 25 console cases in total, so the number of vibration measurements in Case 4 is 25 o Case 5: Turning tool S20R- MTJNR16 with hole and console in environment oil

Describe: There are 25 console cases in total, so the number of vibration measurements in Case 5 is 25

=> The total number of vibration measurements in Step 1 is 77 measurements

Table 4.3: Table of experimental parameters Step 1

Figure 4.18: Mounting diagram when measuring vibration

Step 2: Compare the vibrations of random console turning tool

In this experimental phase, the turning tool S20R-MTJNR16 will be assessed using magnetic fluid and magnetic fields, focusing on console numbers 4, 17, and 21 The study will encompass five specific cases: Case 1 examines the tool in an air environment; Case 2 evaluates its performance in water; Case 3 tests the tool in oil combined with 0g of ferrofluid and a magnetic field; Case 4 analyzes the tool in oil with 6.25g of ferrofluid and a magnetic field; and Case 5 explores the tool in oil with 12.5g of ferrofluid and a magnetic field.

𝛼 3 and non- magnetic 𝛼 3 and magnetic 𝛼 3 and magnetic 𝛼 3 and magnetic

Note: Distance form magnet to turning tool in Step 2 is fixed

Step 3: Summarize and filter data to select the console with the lowest vibration in the oil environment from step 1, then process 25 workpieces in 25 different ferrofluid cases and magnet distances

When machining, there will be magnets, so the mounting diagram is slightly changed Since machining will create vibrations, vibration generators will be removed

The presence of a magnet causes cutting material chips to adhere to the cutting edge, making it essential to use compressed air simultaneously to expel these chips This prevents excessive accumulation, which could lead to potential damage or impact on the cutting tool.

Figure 4.21: Mounting diagram when machining

2.5-gram ferrofluid and 10ml oil

5-gram ferrofluid and 10ml oil

10-gram ferrofluid and 10ml oil

Step 4: Measure the roughness of 25 workpieces machined in step 2 to select the workpiece with the best roughness

After turning the inner hole, there will be swarf so the first thing to do is to remove the swarf

Figure 4.22: Swarf remaining after hole machining

After cleaning the swarf, employ the Mitutoyo SJ-201 roughness meter to assess the gloss of the workpiece Each workpiece should be measured three times at different positions to obtain an average result, ensuring the most accurate and objective findings.

Figure 4.23: Measure the roughness of the workpiece after machining

Figure 4.24: Position of the probe

Step 5: Measure the vibration of the machined console to produce the best- polished workpiece and compare it with the previously measured cases

• Case 1: Turning tool S20R- MTJNR16 default (Step 1)

• Case 2: Turning tool S20R- MTJNR16 with hole (Step 1)

• Case 3: Turning tool S20R- MTJNR16 with hole and console number 4 in environment air (Step 1)

• Case 4: Turning tool S20R- MTJNR16 with hole and console number 4 in environment water (Step 1)

• Case 5: Turning tool S20R- MTJNR16 with hole and console number 4, ferrofluid and magnet (The case with the best roughness)

Specify the cutting mode

Based on the tables of commonly used cutting modes in Viet Duc workshops:

Figure 4.25: The parameter table defines the cutting mode

How to select and filter data on the web

Step 1: Visit the website DynaPredict and login [11]

Step 2: Select Spectral Analysis to open the data store and select the date where the data is measured

Figure 4.27: Choose where to find data on Dyna Predict (1)

- Position 1: Select Spectral Analysis to open data result page

- Position 2:Time period data is represented

- Position 3: Choose a datetime to find data

Step 3:Select the data to get

Figure 4.28: Choose where to find data on Dyna Predict (2)

- At position 1 Machines: Ferrofluid – turning is the name of group

- At position 2 Spots: is the name of the specific instance that was measured in there:

QD is a specific case , number is console number (ex: QD23 is case turning tool in oil environment with console number 23)

- At position 3 Sychronization: is the date the data is synced to the web

- At position 4 Measurement date: is the date on which data is measured

Step 4: Select the quantity you want to survey, includes 3 quantities of Acceleration, Velocity, Displacement

Step 5:Determine the data type

Figure 4.30: Some parameters around the chart

- At position 1: The length of time the sensor receives the oscillations

- At position 2: is the place to show measured values including RMS, PP, CF, KURT with 3 axes with 3 different colors

- At position 3: is where the cylinders are shown on the chart

Figure 4.31: Representation chart of Radial at Acceleration (pink)

EXPERIMENT RESULTS/FINDING AND ANALYSIS

Step 1 Measure the vibration of the turning tool in different environments and compare

After measuring the vibration in 5 cases in step 1, we have the following diagram:

When analyzing the vibration levels of various turning tools, including the default turning tool, the holeless turning tool without a console, and the turning tool with a hole and console, we observe distinct differences in acceleration The accompanying chart illustrates these variations, highlighting the performance disparities among the tools in an air environment.

Figure 5.1: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Acceleration)

Turning tool with Console case Turning tool without hole Turning tool with hole

Table 5.1: Table of additional values for Figure 5.1

Figure 5.2: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Acceleration)

Figure 5.3: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Acceleration)

Figure 5.4: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Acceleration)

Figure 5.5: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Acceleration)

Table 5.5: Table of additional values for Figure 5

Figure 5.6: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Acceleration)

Table 5.6: Table of additional values for Figure 5.6 b Velocity:

Figure 5.7: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Velocity)

Figure 5.8: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Velocity)

Figure 5.9: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Velocity)

Figure 5.10: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Velocity)

Figure 5.11: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Velocity)

Figure 5.12: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole, console in air (Velocity)

Figure 5.13: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in air (Displacement)

Figure 5.14: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in air (Displacement)

Figure 5.15: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in air (Displacement)

Figure 5.16: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in air (Displacement)

Figure 5.17: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in air (Displacement)

Figure 5.18: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in air (Displacement)

In a comparative analysis of vibration levels among three types of turning tools—default turning tool, holeless turning tool without a console, and turning tool with a hole and console in water—acceleration data reveals significant differences.

Figure 5.19: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Acceleration)

Figure 5.20: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Acceleration)

Figure 5.21: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Acceleration)

Figure 5.22: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Acceleration)

Figure 5.23: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Acceleration)

Figure 5.24: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Acceleration)

Figure 5.25: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Velocity)

Figure 5.26: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Velocity)

Figure 5.27: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Velocity)

Figure 5.28: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Velocity)

Figure 5.29: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Velocity)

Figure 5.30: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Velocity)

Figure 5.31: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Displacement)

Figure 5.32: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Displacement)

Figure 5.33: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Displacement)

Figure 5.34: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Displacement)

Figure 5.35: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Displacement)

Figure 5.36: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in water (Displacement)

In a comparative analysis of vibration levels among three types of turning tools— the default turning tool, the holeless turning tool without a console, and the turning tool with a hole and console—results indicate varying acceleration profiles The accompanying chart illustrates these differences in vibration behavior when immersed in oil.

Figure 5.37: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Acceleration)

Figure 5.38: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Acceleration)

Figure 5.39: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Acceleration)

Figure 5.40: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Acceleration)

Figure 5.41: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Acceleration)

Figure 5.42: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Acceleration)

Table 5.42: Table of additional values for Figure 5.42 b Velocity

Figure 5.43: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Velocity)

Figure 5.44: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Velocity)

Figure 5.45: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Velocity)

Figure 5.46: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Velocity)

Figure 5.47: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Velocity)

Figure 4.48: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Velocity)

Figure 5.49: Comparison chart of RMS in X direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Displacement)

Figure 5.50: Comparison chart of RMS in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Displacement)

Figure 5.51: Comparison chart of RMS in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Displacement)

Figure 5.52: Comparison chart of PP in X direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Displacement)

Figure 5.53: Comparison chart of PP in Y direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Displacement)

Figure 5.54: Comparison chart of PP in Z direction between default turning tool, turning tool with hole and turning tool with hole and console in oil (Displacement)

The results obtained in the environments show the console in different cases and there is no specific rule or order of high or low.

Step 2 Compare the vibration of the turning tool in different cases between 3 consoles 4, 17, 21

The results are aggregated and presented in the form of a graph

Have magnetic, oil environment with 0 gram

Have magnetic, oil environment with 6.25 gram

Have magnetic, oil environment with 12.5 gram Console number

Table 5.55: Compare RMS value in Y-axis (Acceleration 𝑚𝑚/𝑠 2 )

Figure 5.55: Compare RMS value in Y-axis (Acceleration)

Table 5.56: Compare RMS value in Z-axis (Acceleration)

Figure 5.56: Compare RMS value in Z-axis (Acceleration)

Table 5.57: Compare PP value in Y-axis (Acceleration)

Figure 5.57: Compare PP value in Y-axis (Acceleration)

Table 5.58: Compare PP value in Z-axis (Acceleration)

Figure 5.58: Compare PP value in Z-axis (Acceleration)

Table 5.59: Compare RMS value in Y-axis (Velocity)

Figure 5.59: Compare RMS value in Y-axis (Velocity)

Table 5.60: Compare RMS value in Z-axis (Velocity)

Figure 5.60: Compare RMS value in Z-axis (Velocity)

Table 5.61: Compare PP value in Y-axis (Velocity)

Figure 5.61: Compare PP value in Y-axis (Velocity)

Table 5.62: Compare PP value in Z-axis (Velocity)

Figure 5.62: Compare PP value in Z-axis (Displacement)

Table 5.63: Compare RMS value in Y-axis (Displacement)

Figure 5.63: Compare RMS value in Y-axis (Displacement)

Table 5.64: Compare RMS value in Z-axis (Displacement)

Figure 5.64: Compare RMS value in Z-axis (Displacement)

Table 5.65: Compare PP value in Y-axis (Displacement)

Figure 5.65: Compare PP value in Y-axis (Displacement)

Table 5.66: Compare PP value in Z-axis (Displacement)

Figure 5.66: Compare PP value in Z-axis (Displacement)

The differences in acceleration, velocity, and displacement are particularly evident in the PP values of displacement quantities Notably, there is a significant distinction in RMS and PP measurements across all three parameters—acceleration, velocity, and displacement—when comparing magnetic and non-magnetic turning tools.

Step 3 Choose the console lowest vibration

5.3.1 The results select the case that the console has the lowest vibration in oil environment

Figure 5.67: Parameter information sheetDescribe:

Position 1: Numbers from smallest to largest

Position 2: Number of console corresponding to the ordinal number

Because the y and z axes are the two axes that affect roughness, we only consider the results on the y and z axes

By adding the total number of positions we have the following table:

Table 5.67: The graph shows the results of selecting the console with the smallest vibration

Comment: with Total result equal to 34, console number 4 is the handle with the smallest vibration Select it to conduct experimental cutting for the next step.

Step 4 Compare roughness

According to the manual arrangement presented in Table 5.67, the cases are organized from smallest to largest The smallest console case identified is console 4, which will be utilized for the subsequent phase of the experiment.

Table 5.68: The result of measuring the roughness of the machined workpiece of the turning tool without holes

Table 5.69: Roughness measurement results 𝑅 𝑎 (𝜇𝑚) Distance (mm)

Avg 29.25 20.6467 13.3933 19.8233 19.7033 Table 5.70: Roughness measurement results 𝑅 𝑍 (𝜇𝑚)

Note: Gap is distance form Magnet to Turning tool

With the amount of ferrofluid 7.5 grams with 5 different distances, most have roughness default turning tool Especially with the case of 5gram ferrofluid 0.9mm distance for 𝑅 𝑎 = 1.07𝜇𝑚 and 𝑅 𝑍 = 6.936667𝜇𝑚.

Step 5 Compare the vibration of the turning tool in some specific cases

5.5.1 Result of Step 5 by chart: a Acceleration:

Figure 5.68: Compare the vibration of the turning tool under different environmental conditions RMS-Y axis (Acceleration)

Figure 5.69: Compare the vibration of the turning tool under different environmental conditions RMS-Z axis (Acceleration)

Figure 5.70: Compare the vibration of the turning tool under different environmental conditions PP-Y axis (Acceleration)

Figure 5.71: Compare the vibration of the turning tool under different environmental conditions PP-Z axis (Acceleration) b Velocity:

Figure 5.72: Compare the vibration of the turning tool under different environmental conditions RMS-Y (Velocity)

Figure 5.73: Compare the vibration of the turning tool under different environmental conditions RMS-Z (Velocity)

Figure 5.74: Compare the vibration of the turning tool under different environmental conditions PP-Y (Velocity)

Figure 5.75: Compare the vibration of the turning tool under different environmental conditions PP-Z (Velocity) c Displacement:

Figure 5.76: Compare the vibration of the turning tool under different environmental conditions RMS-Y (Displacement)

Figure 5.77: Compare the vibration of the turning tool under different environmental conditions RMS-Z (Displacement)

Figure 5.78: Compare the vibration of the turning tool under different environmental conditions PP-Y (Displacement)

Figure 5.79: Compare the vibration of the turning tool under different environmental conditions PP-Z (Displacement)

Image between Turning tool default (Basic tool) and Turning tool with hole, ferrofluid, console number 4 in oil with magned (Best roughness) on the web DynaPredict

Figure 5.80: Acceleration in Y-axis on Basic tool (DynaPredict)

Figure 5.81: Acceleration in Y-axis on Best Roughness (DynaPredict)

Figure 5.82: Accleration in Z-axis on Basic tool (DynaPredict)

Figure 5.83: Acceleration in Z-axis on Best Roughness (DynaPredict)

Figure 5.84: Velocity in Z-axis on Basic tool (DynaPredict)

Figure 5.85: Velocity in Z-axis on Best Roughness (DynaPredict)

Figure 5.86: Velocity in Z-axis on Basic tool (DynaPredict)

Figure 5.87: Velocity in Z-axis on Best Roughness (DynaPredict)

Figure 5.88: Displacement in Y-axis on Basic tool (DynaPredict)

Figure 5.89: Displacement in Y-axis on Best roughness (DynaPredict)

Figure 5.90: Displacement in Z-axis on Basic tool (DynaPredict)

Figure 5.91: Displacement in Z-axis on Best roughness (DynaPredict)

The analysis of vibration parameters reveals that tools with holes containing ferrofluid exhibit low RMS values of 0.0287 mm/s² in the Z-axis and 0.0382 mm/s² in the Y-axis, along with peak-to-peak (PP) values of 0.5044 mm/s² and 0.5451 mm/s², respectively In contrast, the tool with a hole and console in oil shows a higher RMS velocity of 0.7004 mm/s in the Y-axis, while the lowest RMS velocity in the Z-axis is 0.5927 mm/s for the turning tool The highest PP velocity in the Z-axis is recorded at 4.9521 mm/s for the tool with ferrofluid, while the lowest Y-axis PP is 6.163 mm/s for the same tool Regarding displacement, the tool with ferrofluid has the lowest Y-axis RMS at 0.0452 mm, whereas the tool with a console in oil has the lowest Z-axis RMS at 0.0424 mm Additionally, the lowest Y-axis displacement PP of 0.3013 mm belongs to the tool with ferrofluid, while the Z-axis displacement PP of 0.7016 mm is also attributed to the tool with a console in oil Accurate measurements of these vibrations at specific frequencies are crucial for evaluating tool performance.

135 certain period of time, we can conclude that the turning tool with ferrofluid has a significant damping effect with the parameters we consider and compare with other cases

CONCLUSION AND RECOMMENDATIONS

Conclusion

The group has successfully implemented the survey and fulfilled all requirements outlined in this report, presenting the information in the appropriate format This includes a comprehensive overview of the urgency, objectives, and tasks related to the topic Overall, the Graduation Thesis effectively addresses the key issues at hand.

In surveying the lathe table, we apply mathematical and measuring knowledge to inform the design of a jigsaw model for magnets, focusing on key criteria such as durability, cost-effectiveness, and flexibility.

This article analyzes and summarizes the vibration measurement process across five different cases: the original turning tool, a tool with a hole, a tool with a console in air, a tool with a console in water, and a tool with a console in oil Additionally, it includes a survey to determine the optimal roughness for the ferrofluid case.

Designing and manufacturing a magnet bracket requires a practical approach that ensures both flexibility and solidity during the installation of magnets and the fixture on the lathe table.

The potential for enhancement and progress is evident in the identification of trends related to experimental steps, particularly in the precise measurement of vibrations using ferrofluid in console cases 4, 17, and 21.

The specialized software CAE effectively analyzes the load capacity influenced by the magnetic attraction of the magnet on the tool, as well as the subsequent displacement of the magnet and fixture post-installation.

The implementation of ferrofluid in turning tools significantly reduces vibrations during machining processes, particularly under low standards This innovative approach is not only effective but also easy to apply and user-friendly.

In the end, the process of implementing the project has achieved the following specific products:

- An application model is given for turning tool in terms of vibration damping when turning when using ferrofluid

- Accurate measurements of velocity, acceleration, and displacement values of ferrofluid and original turning tool shanks

- Workpieces have lower roughness values than the original turning tool and determine certain magnet spacing and ferrofluid concentrations

- Study the tool direction and cutting trajectory to achieve the best surface finish

- Study of damping on other materials (Aluminium, )

- Learn more about the damper technology of the turning tool

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Palanisamy, Mohit Bajaj, Naveen Kumar Sharma and Kitmo, “Quality and Tool Stability Improvement in Turning Operation Using Plastic Compliant Damper”, Journal of

[3] Dynamox, “DynaLogger TcAs” https://content.dynamox.net/wp- content/uploads/2023/02/en-dynalogger-tcas.pdf (accessed July 24, 2023)

In vibration analysis, accurate signal interpretation is vital for effective predictive maintenance Key metrics such as peak, peak to peak, and RMS values aid in understanding vibration signals The peak value represents the highest amplitude in the signal, while the peak to peak value measures the difference between the maximum and minimum peaks, both indicating potential impacts Conversely, the RMS (Root Mean Square) value reflects the total energy of the signal, providing a comprehensive view of vibratory energy, particularly as fault progression occurs Monitoring these metrics helps in identifying mechanical issues, with RMS values being less influenced by outliers, making them reliable for tracking equipment health over time.

[5] Dymamox, “Vibration analysis metrics: Kurtosis and Skewness” https://dynamox.net/en/blog/vibration-analysis-metrics-kurtosis-and-skewness (accessed July 24, 2023)

[6] A.N.M Khalil, M.A.M Ali, A.I Azmi, “Effect of Al2O3 nanolubricant with SDBS on tool wear during turning process al ANSI 1050 with minimal quanlity lubricant”,

MIMEC2015, University Malaysia Perlis, Malaysia, 2015

[7] Dassteel, “Thép tấm” http://www.thepdonga.vn/thep-tam/thep-tam-aisi-1050.html (accessed July 24, 2023)

[8] MatWeb, “AISI 1050 Steel, as rolled” https://bom.so/eZLtL3 (accessed July 24,

[9] Exapro, “Weiler Praktikant 160B” https://www.exapro.com/sp/weiler- praktikant160b-11700 (accessed July 24, 2023)

[11] https://dyp.dynamox.solutions/signin/session-expired

Tiêu đề	Fabrication Of Damping Models Using Magnetic Fluids (Ferrofluids) Application For Turning Tool
Tác giả	Nguyen Phuc Nam, Le Minh Tri, Pham Thien Quang
Người hướng dẫn	Me. Le Ba Tan
Trường học	Ho Chi Minh University of Technology and Education
Chuyên ngành	Machine Manufacturing Technology
Thể loại	Graduation Project
Năm xuất bản	2022-2023
Thành phố	Ho Chi Minh City

Định dạng
Số trang	173
Dung lượng	12,67 MB