Analyzing the design of vibration reduction with the rubber-layered laminates in the precision turning with a diamond cutting tool

• Published in: International journal of advanced manufacturing technology Vol. 57; no. 1-4; pp. 101 - 116
• Main Authors: Chen, Chih-Cherng, Chiang, Ko-Ta
• Format: Journal Article
• Language: English
• Published: London Springer-Verlag 01.11.2011; Springer Nature B.V
• Subjects: Butadiene; CAE) and Design; Computer-Aided Engineering (CAD; Confidence intervals; Cutting parameters; Cutting speed; Cutting tools; Damping; Design analysis; Diamond machining; Diamond tools; Engineering; Feed rate; Industrial and Production Engineering; Laminates; Materials selection; Mechanical Engineering; Media Management; Original Article; Response surface methodology; Rubber; Silicone rubber; Surface roughness; Turning (machining); Vibration analysis; Vibration control; D-optimal design; Surface roughness; Vibration; Response surface methodology (RSM); Rubber-layered laminate
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-011-3281-y

Using a diamond cutting tool in the precision turning process, the vibration of tool-tip has an undesirable effect on the machined surface’s quality. The objective of this paper is to analyze the design of turning tool-bar combined with the rubber-layered laminates for minimizing the vibration amplitude of tool-tip in the precision turning with the diamond tool. The selected rubber materials are styrene butadiene rubber (SBR) and silicone rubber (SI). Machining parameters, including the spindle speed, feed rate, and cutting depth, were chosen as numerical factors, and the status of the rubber-layered laminates was regarded as the categorical factor. The status of the rubber-layered laminates set up three categories including the solid tool (without rubber-layered laminates), tool with SBR rubber-layered laminate, and tool with SI rubber-layered laminate. An experimental plan of a four-factor (three numerical plus one categorical) D-optimal design based on the response surface methodology was employed to carry out the experimental study. The results show that the design of the turning tool-bar combined with the rubber-layered laminates is proven to improve the damping forces of the turning tool-bar. The overall vibration on the tool-tip using the tool with the rubber-layered laminates tends to be in a more stable condition, which leads to the result of having the best machined surface. With experimental values up to a 95% confidence interval, it is fairly well for the experimental results to present the mathematical models of the surface roughness without/with the rubber-layered laminates.