World Applied Sciences Journal 12 (10): 1814-1818, 2011 ISSN 1818-4952 IDOSI Publications, 2011

Theoretical Cutting Force Prediction and Analysis of Boring Process Using Mathcad
1

T.Alwarsamy, 2S.Vetrivel and 1S. Nadarajan

Department of Mechanical Engineering, Government College of Technology, Coimbatore, India Department of Mechanical Engineering, Bannari Amman of Technology, Sathyamangalm, India

Abstract: Boring is a frequently employed finishing operation in machine shops. Boring is a process in which pre-drilled holes or holes in cast, forged or extruded components are enlarged or finished with a cutting tool mounted on a boring bar. The process is mostly used in applications where close dimensional tolerances and good surface finish are required. In this research work based on the theoretical cutting force model, values of force components have been obtained by using the combination of work piece and tool signature. The cutting forces are theoretically resolved in the tangential force (Ft), feed force (Ff), radial force (Fr) directions. The study of cutting forces of boring process is therefore a prerequisite for selecting appropriate cutting conditions. A predictive cutting force model has been developed and influence of cutting parameters on force components has been depicted as graphs using mathematical tool MathCAD 8 professional software. Key words: Boring Force modeling MathCAD parameters. The cutting forces of boring process is prerequisite for selecting appropriate cutting conditions and also preserving process accuracy by avoiding excessive tool deflections or dynamic vibrations. The tool rake face may be flat or may have grooves or obstructions such as chip breakers.The tool nose radius and the variation of oblique angle along the cutting result in the Non-uniform distribution of chip thickness and consequently the cutting force. Min Wang and Renyuan Fei [3] describes the boring is a frequently employed finish machining operation in machining shops however,because of low righty of boring bar chatter is difficult to be avoided even if the depth is very small. So, chatter is one of the main obstacles to the improvement of the work piece surface finish and tool life boring. Most chatter occurring in boring is regenerative chatter.it can be regarded as the resonance of the boring bar caused by the dynamic cutting force.Since the chatter is unstable to be exterminated the online chatter detection and control are to be the key art to improve the machining stability. C. Mei [4] introduced the Chatter in metal cutting process, in general, is the result of both forced and selfexcited vibrations Forced vibration is due to the unbalance of rotating members, such as unbalanced

INTRODUCTION Boring is a commonly used operation in enlarging holes such as engine cylinder holes. When boring bars are slender and long, the operation is constrained by excessive static deflections or self excited chatter vibrations. Both are detrimental to the accuracy and surface finish of the hole, as well as causing accelerated wear and chipping of the tool. The aim of the research is prediction of analytical force modeling is done by MATHCAD software and corresponding graphs are analysied. Robert G. Landers [1] have been reported that the forces generated when cutting tool and part come into contact produce significant structural deflections.These structural defections modulate the chip thickness that, in turn, changes the machining forces. For certain cutting conditions, this closed loop, self exited system becomes unstable and regenerative chatter occurs. Regenerative chatter may result in excessive machining forces and tool wear, tool failure and scrap parts due to unacceptable surface finish, thus severely deceasing operation productivity and part quality. N.Z. Yussefian et al. [2] have been reported tool deflections or vibrations not only change the true process

Corresponding Author: T. Alwarsamy, Department of Mechanical Engineering, Government College of Technology, Coimbatore, India, E-mail: [email protected].

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driving system, a servo instability, or impacts from a multitooth cutter. In practice, the forced vibration sources can be traced by comparing the frequency of chatter with the frequency of the possible force functions. Self-excited vibration consists of two types, namely primary (or nonregenerative type) and regenerative type. The primary/non-regenerative type of self-excited vibration occurs when there is no interaction between the vibratory motion of the system and the undulatory surface produced in the revolution of the work piece, such as that in threading. Hence it is inherently related to the dynamics of the cutting process. While the regenerative type of self-excited vibration is due to the interaction of the cutting force and the work pieces ur face undulations produced by previous tool passes.The regenerative type of self-excited vibration is found to be the most detrimental phenomena in most machining process, hence it becomes the focus of this paper The regenerative type of self-excited vibration is found to be the most detrimental phenomena in most machining process. D.G. Lee [5] have been reported the shape of a boring bar is long and slender. Therefore, the dynamic stiffness of the boring bar is usually low and chatter vibration in boring operation is primarily caused by inevitably low dynamic rigidity of the boring bar. In order to improve the stability against chatter vibrations, various types of boring bars have been devised by several researchers. F. Atabey et al. [6] have been reported as the enlargement of holes is achieved via boring operations. The hole diameter is either enlarged with a single insert attached to a long boring bar, or with a boring head which has a diameter equal to the diameter of the hole to be enlarged. Long boring bars statically and dynamically deform under the cutting forces during boring operations. Excessive static deflections may violate the dimensional tolerance of the hole and vibrations may lead to poor surface, short tool life and chipping of the tool. Predictions of the force, torque and power are required in order to identify suitable machine tool and fixture set up for a boring operation. A comprehensive engineering model, which allows prediction of cutting forces, torque, power, dimensional surface finish and vibration free cutting conditions, is required in order to plan boring operations in the production floor. A. Kumagai et al. [7] have been reported a Boring operation is one of the most important machining operations. To control the precision and quality, boring tools must be in good condition during boring machine operations.

Fig. 1: Cutting forces On-line monitoring of boring tool conditions has been conducted in this work. A piezoelectric dynamometer was used to measure cutting forces in the tangential, longitudinal and radial directions. In other words, cutting forces were used as indices for the monitoring of boring tools because cutting forces are closely related to the process and are capable of indicating tool conditions. In this research work based on the cutting forces prediction based on the relationship between work piece and tool signature by using MATHCAD software. F. Atabey et al. [8] introduced the sample boring head with two inserts is used. The inserts are arranged with symmetrical angular positions on the boring head in order to cancel the forces on the inserts in X and Y directions, hence the total force in the XY plane is aimed to be zero. The force cancellation leads to better tolerances with multi-insert boring bars with a large operational length-to diameter ratio (L/D), provided that the inserts are symmetrically aligned and located on the boring head without off sets or process faults. Three cutting force components, tangential, radial and feed forces (Ft, Fr and Ff) act on each boring head insert as presented in Part I of the article. The tangential (Ft)and radial (Fr) forces are combined to give resultant force FR,i (i is the insert number) in the XY plane which is perpendicular to hole axis (Fig. 1). The feed and radial forces are calculated from friction force (Ffr) and effective lead angle (fL). The cutting forces are expressed as functions of chip load (A) and chip-cutting edge contact length (Le) and cutting coefficients.

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F. Atabey et al. [9]. The boring inserts have nose radius and may have either uniform or irregular rake face. The distributions of chip thickness, therefore the cutting pressure amplitude and direction, vary as a function of tool nose radius, radial depth of cut and inclination angle. Since the boring bar is long and flexible, it is not possible to remove much larger depths of cuts than the nose radius of the tool, unlike the case of turning and face milling operations. This leads to a non-linear, complex relationship between the cutting force distribution, tool geometry, federate and depth of cut. Furthermore, the presence of static and dynamic deflections may influence the engagement conditions, leading to variations in chip load distribution and the cutting pressure. The cutting forces are usually predicted as a function of uncut chip area that changes in a complex manner in boring due to nose radius and geometry of the tool and cutting conditions. If the tool rakes face has an irregular geometry due to chip breaking grooves and chip-tool contact restriction features, the cutting coefficients are identified using mechanistic models. Ismail Lazoglu et al. [10] have been identified The flexible boring bar initially experiences transient vibrations, which rapidly leads to unstable chatter vibrations if the radial depth of cut, speed and feed are not properly selected. The boring process has some fundamental differences from the milling operations, where the axial depth of cut is mostly larger than the nose radius of the insert and the vibrations are lateral. As a result, the chip load distribution and vibrations do not influence the direction of cutting forces (i.e., cutting coefficients) as well as the axial depth of cut, which are the main parameters in determining stability. In this paper presents the prediction of theoretical cutting force model based on the work piece and tool signature. The progress is carried out by using MATHCAD 8 professional software and corresponding graphs are analyised. Methodology Mechanistic Modeling of Cutting Forces: Basically boring operation need for three cutting forces of the components, tangential, radial and feed forces (Ft, Fr and Ff) act on each boring head insert from fig. 1. Orthogonal Tests and Identification of Oblique Parameter: Orthogonal cutting parameters, shear stress (ts), friction angle (ba), chip compression ratio (rc) have been identified by carbide tools and boring bar(S25TPCLNR12F3)material as functions of feedrate(c) and cutting speed (V) as follows:

Fig. 2: Cutting force occurs in boring operation ba[deg] = 33.69-12.16c-0.022V [a] rc = 0.227 +2.71c + 0.00045V [b] where c is the feed rate in mm/rev, V is the cutting speed in m/min. The expressions are valid within 5,rake angle range. Edge cutting coefficients Kte, Kre and Kfe (units are given in N/mm) have been also identified by Kte = 0.1199 *10-3V2-0.1487V + 76.85 Kfe = 0.1366 *10-3V2-0.2007V + 97.98 [1] Kre = Kte.sin(i) Identifications of the Cutting Force Coefficients: The cutting force coefficients are determined for one selected inserts (CNMG120408 MJ VP10RT (PVD miracle coating).) used in boring process Gun metal work piece material. The procedure is general and applicable to other insert geometries as well. The tangential (Ft) and friction (Ffr) forces are modeled as follows and the force occurring in boring operation shown in fig.2 Ft = Ktc.bh + Kte.b Fr = Krc.bh + Kre.b [2] Ff = Kfc.bh + Kfe.b The Cutting Force Coefficients Are Defined as Follows
Ktc = Kfc = Krc = s Sin( n) cos ( n- an)+tan(i)tan( )sin( n) (cos2 ( n+ n- an)+tan2 ( )sin 2 ( n) sin( n- an)
2 2

s Sin( n)cos ( i ) s Sin( n)cos ( i )

[3]

(cos ( n+ n- an)+tan ( )sin 2 ( n) cos ( n- an)+tan( )sin( n) (cos2 ( n+ n- an)+tan2 ( )sin 2 ( n)

Analytical Simulation of Cutting Forces Using Mathcad Software: The simulation is carried out by selecting following input parameters., oblique angle 15, normal rake 1816

World Appl. Sci. J., 12 (10): 1814-1818, 2011

Graph 1: (Tangential force) Fig. 3: MathCAD simulation

Table 1: Ft(N) 18.83 22.60 30.13 33.90 37.66 41.43 45.20 48.96 52.47 56.22 59.96 63.71 67.46 71.21 Ff(N) 20.68 24.13 27.57 31.02 34.47 37.92 41.36 44.81 48.23 51.67 55.12 58.56 62.10 65.45 B(mm) 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Graph 2: (Feed force)

angle 25, normal shear angle 25, normal friction angle 35, orthogonal angle 15, shear strength 140N/mm2, work piece diameter 150mm, speed 1000rpm. The MathCAD simulation software as shown in fig.2 The simulation of the force model from equation [2] The equations are solved and simulation results are tangential (Ft) and feed force (Ff) shown below table 1 and the corresponding tangential force and feed force are shown in graph (1&2). Condition (i): Cutting speed are selected V=100 to1000rpm From the above table value 1 and the tangential force and feed force graph (1&2) is consecutively the increasing cutting speed obviously cutting force should be decreased naturally.

Graph 3: (Tangential force)

Graph 4: (Feed force) 1817

World Appl. Sci. J., 12 (10): 1814-1818, 2011

Table 2: Ft(N) 18.83 22.60 30.13 33.90 37.66 41.43 45.20 48.96 52.47 56.22 59.96 63.71 67.46 71.21 Ff(N) 20.68 24.13 27.57 31.02 34.47 37.92 41.36 44.81 48.23 51.67 55.12 58.56 62.10 65.45 B(mm) 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

REFERENCE 1. Robert G. Landers Regenerative chatter in machine tools by university of Missouri at Rolla. 2. Yussefian, N.Z., B. Moetakef-iman and H. ElMounayri, 2008. The prediction of cutting force for boring process International J. Machine tools and Manufacture. pp: 48. 3. Min Wang and Renyuan Fei 2000. Online chatter detection and control in boring based on electro rheological fluid school of Mechanical Engineering, Beijing Polytechnic University. 4. Mei, 2004. Active regenerative chatter suppression during boring manufacturing process Department of Mechanical Engineering, The University of Michigan-Dearborn. 5. Lee, D.G., 1998. Manufacturing and Testing of chatter free boring bars Korea institute of technology-sponsored by N.P. Suh(1), MIT., 6. Atabey, Lazoglu, F. and Y. Altintas 2002. Mechanics of boring processes-Part I University of British Columbia, Department of Mechanical Engineering, Manufacturing Automation Laboratory, Canada, 7. Kumagai a, A., Y.C. Wanga, S.D. Song a, Z. Fua and J. Lee, On-line monitoring of boring tools for control of boring operations T.I. Liu a,n, b a Department of Mechanical Engineering, California State University. 8. Atabey a, F., I. Lazoglu b. and Y. Altintas 2002. Mechanics of boring processes-Part II-multi-insert boring heads University of British Columbia Department of Mechanical Engineering Manufacturing Automation Laboratory, Canada, 9. Atabey a, F., I. Lazoglu b. and Y. Altintas 2002. Mechanics of boring processes-Part I University of British Columbia, Department of Mechanical Engineering, Manufacturing Automation Laboratory, Vancouver, Canada, 10. Ismail Lazoglu, Fuat Atabey. and Yusuf Altintas, 2002. Dynamics of boring processes: Part III-time domain modelingKoc University, Department of Mechanical Engineering, Turkey,

Condition (ii): Depth of cut are selected B=.5 to 2 mm From the above table value 2 and the tangential force and feed force graph(3&4) is consecutively the increasing depth of cut obviously cutting force should be increased. CONCLUSION In this paper a new analytical cutting force model obtain from the information related to the work piece and tool signature for a boring operation. The cutting forces are theoretically resolved in the tangential force (Ft), feed force (Ff), radial force (Fr) directions. When the cutting force decreases with increasing in cutting speed. In all machining concept depth of cut increases obviously increasing Cutting force hastily, hence theoretically proved. A predictive theoretical cutting force model has been developed and influence of cutting parameters on force components has been predicted as graphs using mathematical tool MathCAD 8 professional software. In future the experimental values will be adopted and compare the results.

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