COB-2023-2364
ANALYSIS OF THE MACHINING FORCES AND VIBRATIONS IN
TURNING WITH GROOVING TOOLS
Amarildo Alves Dias
Milton Luiz Polli
Federal University of Technology - Paraná, Graduate Program in Mechanical Engineering and Materials – PPGEM. Deputado Heitor
Alencar Furtado Street, 5000 –CIC, Curitiba – PR, 81208-340.
[email protected][email protected]Abstract. Among current manufacturing processes, machining stands out as one of the main means of production. The
turning process is extremely important in the manufacturing of various parts. Vibration, or the phenomenon of self-
excited vibrations that occur mainly due to the low dynamic rigidity of the cutting tool or the workpiece, compromises
surface finish, dimensional accuracy, and tool life. Wide-channel turning with groove tools offers a significant time gain
compared to the use of right or left cutting geometries. However, research addressing the occurrence of regenerative
vibrations in this type of process is scarce. This study analyzed the dynamic stability in the turning process with groove
tools. Experimental tests were conducted on a CNC lathe, with variations in cutting parameters and workpiece overhang.
The material used in the tests was 1045 steel. Machining was performed without cutting fluid using the N123G2-0300-
0004-TM 1125 insert. Stability evaluation was based on the analysis of the audio signal and machining forces. The
results showed that the machining forces increase linearly with the federate and there is a clear improvement in stability
with the reduction of the workpiece overhang during machining.
Keywords: Channel turning, regenerative vibrations, grooving tool, chatter, machining stability.
1. INTRODUCTION
Due to its flexibility of use, high production capacity combined with great dimensional and geometric precision,
machining, along with its sub-processes, is present in the production chain of most industrialized products. It also provides
high-quality surface finishes for a wide range of geometries with a good cost-benefit ratio (Lauro et al., 2014).
Machine tools and cutting tools have evolved considerably in recent years. Regarding machine tools, they have
become more powerful, precise, rigid, and with a higher level of automation. However, some problems persist in this
process, such as limitations, for example, vibrations, which at certain levels can increase production costs, reduce
productivity, waste raw materials, and contribute to increased noise in the environment (Munoa et al., 2016; Quintana
and Ciurana, 2011). In machining operations, the machine tool, cutting tool, workpiece, and cutting conditions form a
vibratory system with dynamic and complex behavior (Lim, 1995). While free and forced vibrations are easily identifiable
and have trivial solutions, in regenerative (self-excited or chatter) vibrations, control is complex due to the variety of
components that can affect the stability of the system during machining (Siddhpura and Paurobally, 2012; Quintana and
Ciurana, 2011). The forces that contribute to the occurrence of this type of vibration do not originate from factors external
to the cutting process, but from resulting forces generated during it (Pires, 2011; Polli, 2005).
According to Altintas (2012) the self-excitation mechanism occurs when one of the structural modes of the machine-
tool-part system is initially excited by the cutting forces. The regenerative effect is caused by the superimposition of
successive cuts, when the tool passes over an undulating surface on the workpiece with a phase change between successive
undulations. The lack of synchronism between the passes ((Figure 1) causes the chip thickness to vary exponentially with
consequent variation of the cutting forces, exciting the structure which may have its amplitude of vibration increased if
the excitation frequency is close to a dominant structural mode of the system (Saravanamurugan, et al. 2015; Lara, 2017).
Figure 1. Regenerative effect (Adapted from Atabey, 2001).
A. A. Dias and M. L. Polli
Analysis of the Machining Forces and Vibrations in Turning with Grooving Tools
In turning operations, regarding process instability, studies mainly focus on internal machining due to the fragility of
the tool holder. Studies on vibration control methods have also been conducted for radial cutting with a lathe tool.
In wide channel machining, the use of interchangeable carbide insert lathe tools represents a viable alternative since
this tool can machine in both directions (right and left) and also avoids the need to change the tool for removing the
remaining material on one side of the channel, as in the case of a conventional turning tool (Figure 2).
Figure 2. Machining comparison with a turning tool and a left-hand tool.
This work aims to gain a better understanding of the phenomena associated with the dynamics of the channel turning
process with a lathe tool and how cutting parameters influence the dynamic stability of the process.
2. EXPERIMENTAL PROCEDURE
The analysis of the dynamic stability of the studied process consisted of practical and systematic tests in a machining
laboratory. In order to obtain input data for future computer simulations, tests were conducted to measure the components
of machining force, thus obtaining the cutting coefficients for the tool-workpiece pair at this stage. In the analysis of
process stability, audio signals were recorded during the experiments using a conveniently positioned smartphone to
minimize interference from other sound sources. The data obtained by varying the test conditions (workpiece rigidity and
cutting parameters) were analyzed using specific software.
2.1 Materials and Equipment
The measurement of machining forces was carried out using a Kistler piezoelectric dynamometer (model 9265B) and
a signal amplifier (model 5070A), along with a National Instruments data acquisition board and a personal computer
running LabView software. The sensitivity adjustment of the signal amplifier was set for forces up to 1.5 kN. The
LabVIEW programming was designed so that the input voltage values (V) were displayed in force units (N).
Tests were conducted to measure the components of machining force on both a conventional lathe (Romi, Model ID-
20) and a CNC lathe (Romi, Model GL-240) for result comparison. The same cutting parameters were used in both tests.
For measuring the forces on the CNC machine, two fixtures were fabricated, one for attaching the dynamometer to the
tool turret of the lathe, and another for securing the tool to the dynamometer (Figure 3).
Figure 3. Detail of the dynamometer attachment on the CNC lathe.
27th ABCM International Congress of Mechanical Engineering
December 4-8, 2023. Florianópolis, SC, Brazil
The cutting tool used in this study is specific for axial cutting operations with lateral feed and has the TM cutting
geometry from the manufacturer Sandvik. The manufacturer also provides tools with CM profile for radial cuts. Figure 4
shows the details of the tool geometry, as well as the main angles and cutting data for the ISO P material class (steels)
provided by the manufacturer.
Figure 4. Geometry and parameters of the insert - N123G2-0300-0004-TM 1125 (Adapted from Sandvik, 2020).
Regarding the tool holder, considering that the maximum depth is the characteristic that supposedly has the most
influence on the rigidity of the tool holder, a commonly used holder for turning operations was chosen to avoid extremes
in this regard. Thus, the tool holder used was the RF123G20-2020B, designed for a maximum depth of 20 mm, providing
a moderate rigidity based on this aspect and suitable for the purpose of this work. The tool holder is also from Sandvik.
The raw material used in the tests was the ArcelorMittal's round drawn SAE 1045 steel, with dimensions illustrated
in Figure 5. According to conducted tests, the samples used comply with the manufacturer's specifications, both in terms
of chemical composition and physical.
Figure 5. Raw material used in the tests.
The dimensions of the material used were determined based on preliminary machining tests. This ensures a secure
fixation, appropriate free length (overhang), and sufficient rigidity for the test conditions and objectives of this research.
For audio signal acquisition, a dedicated smartphone Samsung model SM A310M/DS was used. During the
experiments, in order to achieve better sound capture, the machine door was kept open. Two softwares (Matlab R2023a
and Audacity 3.3.3) were used for data analysis. Audacity was used to define the periods of stable and unstable cutting,
while Matlab was utilized to determine the frequencies at peak and to obtain the RMS value during the analyzed period.
2.2 Test Method
To measure the components of machining force (cutting force Fc, feed force Ff, and passive force Fp), the workpiece
was fixed with a small overhang and the values of depth of cut (ap) and cutting speed (Vc) were set to 1.25 mm and 50
m/min, respectively. The values of feedrate ranged from 0.1 to 0.25 mm/rev. Three tests were made for each condition
and the average values were considered in the analysis. The workpiece geometry was prepared according to Figure 6.
Figure 6. Workpiece geometry for measuring machining forces.
A. A. Dias and M. L. Polli
Analysis of the Machining Forces and Vibrations in Turning with Grooving Tools
For all the tests the workpiece was fixed using a 3-jaw Autoblock chuck, model 150 BH, with hydraulic actuation.
For the stability tests, the workpiece overhang (free length of the workpiece) was three times the diameter of the
workpiece, without the use of a tailstock for support at the free end. The clamping pressure was set at 15 bar (1500 kPa).
Figures 7 illustrates the proposed method for turning operations using a tool bit. To preserve the cutting edge of the tool
under analysis and not influence the results, finishing passes were applied to all machined diameters using a "V" profile
tool with a 0.4 mm corner radius, reducing the diameter by 0.5 mm.
Figure 7. Test with variation in depth of cut.
3. RESULTS AND DISCUSSIONS
3.1 Machining Forces
Among the cutting parameters, cutting speed is the one that most influences tool wear. Therefore, at this stage, values
below those recommended by the manufacturer were chosen in order to preserve the cutting edge. However, care was
taken to prevent the formation of built-up edge (BUE), which, according to Reis (2000), occurs due to significant frictional
forces between the chip and the cutting tool under certain machining conditions, especially at low cutting speeds.
Figures 8 to 11 show examples of force measurement with variation in feedrate, which were used to determine the
force coefficients. The values of depth of cut and cutting speed were 1.25 mm and 50 m/min, respectively.
Figure 8. Average value of machining forces for f = 0.10 mm/rev.
27th ABCM International Congress of Mechanical Engineering
December 4-8, 2023. Florianópolis, SC, Brazil
Figure 9. Machining forces for f = 0.15 mm/rev.
Figure 10. Machining forces for f = 0.20 mm/rev.
Figure 11. Machining forces for f = 0.25 mm/rev.
A. A. Dias and M. L. Polli
Analysis of the Machining Forces and Vibrations in Turning with Grooving Tools
The same cutting condition was tested in both right and left feed directions, extracting the most stable intervals for
force recording. In all the experiments, the period of greater stability coincided with the right feed direction, which can
be justified by the slight inclination of the cutting edge of the tool, approximately 0.1 mm over a length of 8 mm. This
reduced the contact area with the workpiece, leading to increased stability in the machining forces.
The negative values in the results may be due to the orientation of the applied load, which can be opposite to the
orientation of the piezoelectric sensor of the dynamometer. Therefore, the negative signal was ignored, and the absolute
value of the average forces was considered.
The forces obtained for all tested parameters showed consistent values. According to Altintas (2012), in the
composition of the cutting force (Fc) and feed force (Ff), additional forces due to tertiary deformation, friction, and chip
compression effect are also included. Unlike the mechanistic mathematical model that uses the Kienzle equation to obtain
the components of the machining force (Fu), Altintas' model considers that the cutting and feed forces are composed of
shear forces (Fcc and Ffc) and forces at the cutting edges (Fce and Ffe). Therefore, it is necessary to determine the shear and
edge cutting coefficients. Figure 12 shows the evolution of the mean forces and the linear regression with the characteristic
equation of each component of Fu , where the slope and intercept correspond to the shear forces and forces at the cutting
edge, respectively.
Figure 12. Evolution of machining forces in function of the feedrate (ap = 1.25 mm; Vc = 50 m/min).
Table 1 shows results obtained in the measurements of machining forces with variation of feedrate. The cutting
coefficients and forces at the cutting edge were obtained based on the characteristic equations obtained from the linear
regression shown in Figure 12.
Table 1 - Results of machining force measurements.
Feed rate Kcc Kfc Kce Kfe Fce Ffe
Fc (N) Ff (N) Fp (N)
(mm/rev) (N/mm2) (N/mm2) (N/mm) (N/mm) (N) (N)
0,10 552 193 111 2936 1016 169,6 61,6 212 77
0,15 793 280 156 2936 1016 169,6 61,6 212 77
0,20 966 339 194 2936 1016 169,6 61,6 212 77
0,25 1106 385 224 2936 1016 169,6 61,6 212 77
Kcc - Shear cutting force coefficient; Kfc - Shear feed force coefficient; Kce - Edge cutting force coefficient; Kfe - Edge feed force
coefficient.
3.2 Process Stability Analysis
For stability tests, the insert was aligned. In the 8 mm length, a maximum misalignment of 0.01 mm was observed.
To verify the cutting edge height, the workpiece was faced with it. The absence of remaining material in the center of the
workpiece indicated that the tool height was correct in relation to the center of the machine.
27th ABCM International Congress of Mechanical Engineering
December 4-8, 2023. Florianópolis, SC, Brazil
The instability in the machining process can be observed through the increase in audio signal amplitude and also by
the appearance of the machined surface. The frequencies during moments of instability were recorded for future
comparisons with the natural frequencies of the tool and the workpiece. In this study, the criterion used for stability
analysis was the sound amplitude, obtained based in the RMS (Root Mean Square) value, which represents the effective
amplitude of the audio signal. The amplitude was obtained considering the entire machining period, as shown in Figure
13. Therefore, the recorded intensity was more affected by the instability duration rather than the sound amplitude itself.
Figure 13. Audio signal in turning with the insert tool.
Table 2 presents the RMS values and frequency at instability peaks for each of the four workpiece overhang values.
Table 2. Results of stability tests with variation in cutting depth.
Overhang Depth Frequency Overhang Depth Frequency
Value RMS Value RMS
(E) (mm) (Hz) (E) (mm) (Hz)
0.25a 0.29 758 0.25a 0.26 747
0.25b 0.10 690 0.25b 0.05 788
0.50a 0.28 759 0.50a 0.25 876
0.50b 0.30 697 0.50b 0.09 800
0.75a 0.26 752 0.75a 0.11 783
E1 E3
0.75b 0.17 759 0.75b 0.10 793
1.00a 0.29 692 1.00a 0.13 781
1.00b 0.31 692 1.00b 0.14 787
1.25a 0.20 671 1.25a 0.15 1001
1.25b 0.29 695 1.25b 0.16 990
0.25a 0.28 759 0.25a 0.26 869
0.25b 0.05 761 0.25b 0.05 773
0.50a 0.26 703 0.50a 0.08 876
0.50b 0.15 726 0.50b 0.08 787
0.75a 0.12 752 0.75a 0.08 783
E2 E4
0.75b 0.13 761 0.75b 0.09 777
1.00a 0.20 760 1.00a 0.11 780
1.00b 0.19 760 1.00b 0.12 750
1.25a 0.18 755 1.25a 0.13 1030
1.25b 0.21 756 1.25b 0.13 1005
Unstable Little Unstable Stable
A. A. Dias and M. L. Polli
Analysis of the Machining Forces and Vibrations in Turning with Grooving Tools
The results were obtained from the tests with variation in depth of cut. The letters (a) and (b) next to the depth values
represent the left and right feed rates, respectively.
The unit of measurement for the RMS value obtained in the tests depends on the unit of the original signal, which,
being collected by a smartphone, does not have a clearly defined physical unit. Therefore, the value found represents a
relative measure of the energy level for each test. For moments of stability in the cutting process, the RMS value remained
below 0.15, while for RMS values above 0.25, vibrations occurred during machining. Intermediate values showed little
instability.
In comparison between the results in E1 and E4, the tests showed a significant improvement in machining stability
with the reduction of workpiece overhang. However, for the number of tests conducted, the cutting depth did not have a
significant influence on the cutting process. Regarding the frequency at moments of maximum sound amplitude, there
was some variation with changes in the workpiece geometry and overhang. The frequency of the oscillation ranged from
671 Hz to 1030 Hz.
4. CONCLUSIONS
The results showed that the machining forces increase linearly with the feedrate. The cutting force is almost three
times greater than the feed force, which in turn is 70% higher than the passive force. It was possible to determine the
shear force constants and edge coefficients for this particular combination of cutting tool and workpiece.
Regarding the stability of the process, based on the number of tests conducted, there is a clear improvement in stability
with the reduction of the workpiece overhang during machining. The alignment of the insert balanced the moments of
instability in both cutting directions. There was no evidence of increased instability with greater depth of cut, which can
be justified by the higher cutting force and consequently greater lateral deflection of the tool. Another factor to consider
in the tests is the reduction in the diameter of the workpiece, as smaller radii of curvature increase the clearance between
the tool and the workpiece, resulting in less friction and a greater tendency for vibrations.
It is necessary to perform modal analysis of the components to determine whether vibrations occurred in the cutting
due to the tool or the workpiece flexibility. The variation in moments of instability throughout the tests, as the workpiece
geometry changed, suggests that the natural frequencies of the workpiece are close to the recorded peak frequencies.
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6. RESPONSIBILITY NOTICE
The authors are the only responsible for the printed material included in this paper.
