Experimental Study of Vibration Frequency-Domain Properties of Aluminum and Nylon Turning Materials

Transcription

1 217 Aia-Pacific Engineering and Technology Conference (APETC 217) ISBN: Experimental Study of Vibration Frequency-Domain Propertie of Aluminum and Nylon Turning Material Shi-Chuang Zhuo and Shun-Cai Li ABSTRACT In order to compare the vibration propertie of different turning material, we ued the CNC lathe and carried out ome turning experiment on the aluminum bar and nylon rod with the ame dimenion. By vibration ignal analyzer and piezoelectric acceleration enor, we picked the vibration ignal of the upper tool urface under different turning parameter. By the frequency domain analye, we have obtained the changing rule of the average value ρ of the maximum auto-power pectral denity in all turning experiment of the two experimental cheme. Experimental tudie how that: (1) when the pindle peed i 1 r/min, the tool vibration correponding to the two kind of material i the mallet. (2) With the increae of the feed rate, the elf power pectrum value of tool vibration during aluminum turning continue to decreae, while the value increae during nylon turning. (3) When the pindle peed i more than 7r/min, both the average value ρ correponding to the two turning material reduced and at lat their value tended to the ame. INTRODUCTION Turning vibration i a kind of dynamic untable phenomenon which occur in the cloed loop ytem of the machine tool, reducing the machining accuracy of part urface, tool wear and breakage, producing a eriou cutting noie. With the development of cience and technology and ociety, a variety of material to meet the need of human production and life are emerging, machining area often need to carry out a variety of metal material, ynthetic material, inorganic non-metallic material and compoite material, uch a cutting, milling, planning and other procee. A lot of theoretical reearch and experimental reearch have been carried out on the caue, hazard and control meaure of cutting vibration. In cutting Shi-Chuang Zhuo 1,a, Shun-Cai LI 2, b 1 School of Phyical & Electrical Engineering, Jiangu Normal Univerity, Xuzhou, Jiangu , China 2 School of Mechanical & Electrical Engineering, Jiangu Normal Univerity, Xuzhou Jiangu , China a zclc@263.net, b @qq.com 1156

2 vibration teting of metal and alloy apect, Ahmed Syed Adnan [1] pointed out that the AL-224 i ubjected to the lateral vibration turning tet under different cutting peed, feed rate and vibration amplitude. The cutting force, chip thickne and urface finih are meaured. The reearch how that the main cutting force and feed direction are reduced, and the chip thickne i decreaed, and the finih i increaed. LIU Weimin [2] tudied tool wear and tool life by uing Al 2 O 3 baed ceramic cutting tool to dry turning 3M ultra high trength teel in high peed, Provide reaonable cutting parameter for the Al2O3 baed ceramic tool dry turning 3M ultra high trength teel. GE Ying-fei [3] tudied ultra preciion turning machining performance of Silicon carbide particle reinforced aluminum matrix compoite (SiCp/Al), experiment how that the machinability of SiCp/Al i poor. ZHU Xuechao [4] tudied the influence on urface roughne about cutting parameter, tool radiu and chamfer in the proce of PCBN cutting tool in dry cutting of hardened teel SKD11. X. Ding [5] tudied the behavior and mechanim of cutting ingle crytal 661T6 Al by uing ingle crytal diamond micro cutter, the reearch how that the tructure of ingle crytal, uch a the ize of particle and the direction of particle, ha an important influence on the cutting force, chip formation and urface finih. Nearly ten year, machining performance and vibration characteritic of non metallic material have become one of the hot reearch iue in machining field. Jeong-Du Kim [6] tudied the ultraonic vibration turning of carbon fiber reinforced platic, compared with normal turning; it can effectively reduce the turning force and improve the urface quality of the work-piece. Ming Zhou [7] tudied the tool wear and urface finih of diamond cutting optical gla by conventional turning and ultraonic machining, ZHOU Zhen-tang [8] carried on the turning tet to the proceing ceramic of the fluorine gold mica by uing high peed teel, hard alloy and Si3N4 ceramic cutting tool to tudy the effect of tool material on the material removal rate and urface finih quality. Peng [9] tudied the effect of vibration on the tool urface and wear during the machining of brittle material with elliptical ultraonic aited cutting. Reearch how that, compared with conventional turning, thi kind of ultraonic aited machining make the brittle material can be removed by ductility, and the tool wear i reduced. Ming Zhou [1] tudied the effect of tool vibration on brittle ductile tranition mechanim by ultraonic diamond cutting gla experiment. In ummary, while the turning performance of metal, nonmetal, compoite material i tudied, But the quantitative reearch reult on the vibration characteritic of different material are very few, In thi paper, the vibration of the tool urface i collected by the acceleration enor, And QLVC-ZSA1 vibration ignal analyzer i ued to analyze the maximum power pectrum of the cutting tool on the urface of the tool. A ingle factor experiment wa ued to tudy the vibration characteritic of the upper and lower urface of the aluminum rod and the nylon rod with different pindle peed and feed rate. TURNING EXPERIMENTS Experimental Condition Thi experiment take the CJK6136-MATE-36 * 57 a the platform of CNC lathe, the tool i the lathe tool, the tool model i SCLCR22M12DE.the diameter 1157

3 and length of the aluminum rod and nylon ued i 22mm and 2mm. When the clip i intalled, the elongation i 85mm and the cutting length i 75mm. Experimental Method Two piezoelectric acceleration enor are intalled on the upper and lower urface of the tool bar, a hown in Fig. 3. Signal acquiition and analyi by QLVC-ZSA1 type vibration analyzer, a hown in Fig. 4, frequency domain analyi of the obtained time domain curve to record the maximum value of the auto power pectrum ρ. Two kind of turning cheme for aluminum rod and nylon rod are a hown in Table 1. Scheme 1: Study on the influence of different feed rate v on the turning vibration. Setting the pindle peed n=6r/min, turning depth a p =.5mm, feed rate were v=69.5mm/min, 136mm/min, 273 mm/min. In each tage of feed rate, the ame work piece i carried out for 4 time in a row. Scheme 2: Study on the influence of different pindle peed n on the turning vibration. Setting the feed rate v=69.5mm/min, turning depth a p =.5mm and pindle peed n= 6 r/min, 7 r/min, 9 r/min, 1 r/min repectively. In each tage of the pindle peed, the ame work piece i carried out for 4 time in a row. Figure 1. Aluminum bar. Figure 2. Nylon bar. 1158

4 Figure 3. Acceleration enor. Figure 4. Vibration ignal acquiition and analyi ytem. Table 1. Experimental cheme of turning. Scheme n(r/min) v(mm/min) Total feed number Scheme 1 6 Scheme According to the tet cheme, the time domain curve are obtained, and then the correponding auto power pectrum i obtained by oftware analyi. Finally, the maximum auto power pectrum i obtained. A hown in Fig. 5, the time domain and frequency domain curve of the pindle peed 6 r/min and feed rate of 69.5 mm/min of aluminum rod

5 (a)time-domain curve ( 1 m ) f( Hz( (b)auto-power pectrum curve Figure 5. Curve of time domain and frequency domain. EXPERIMENTAL RESULTS AND ANALYSIS The Effect of Feed rate on Turning Vibration According to the tet cheme 1, 4 turning tet of aluminum rod and nylon rod were carried out, The time domain curve of the vibration ignal i obtained, The maximum auto power pectral denity of the vibration ignal on the urface of the cutter bar i recorded, the average value of the maximum auto power pectrum of the 4 turning i calculated, a hown in Table 2. Table 2. Power pectrum denity ρ(1-3 m 2-3 ) under different feed peed. Material v(mm/min) ρ(1-3 m 2-3 ) feed 1 feed 2 feed 3 feed 4 Average Aluminum rod Nylon rod According to Table 2, the change curve of the maximum value of the auto power pectrum of the aluminum rod and nylon rod under the four feed tet at different feed peed i obtained a hown in Fig. 6. The change of the average value ρ in the 4 tet with the feed rate i hown in Fig

6 25 /1 m Aluminum bar Nylon bar Feed Number 12 (a)v=69.5mm/min /1 m aluminum bar Nylon bar /1 m (b) v=136mm/min aluminum bar nylon bar Feed Number (c) v=273mm/min Figure 6. The vibration comparion of the two turning material. We can ee from the Fig. 6, when the aluminum rod i turned at the feed rate 69.5 mm/min, 136mm/min, the ρ value increaed lowly with the increae of the number of the pa; when the feed rate increae to 273mm/min, the ρ value i decreaed lowly with the increae of the number of the pa. From the Fig.6, when the nylon rod i turned at the feed rate 69.5 mm/min, the ρ value increae rapidly with the increae of the number of turning; When the feed rate increae to 273mm/min, the ρ value change i relatively table, the overall trend i increaed with the increae of the number of turning, the ρ value of fourth time the pa i lightly higher than the firt pa. 1161

7 25 2 aluminum bar nylon bar /1 m v / mm min Figure 7. Curve of the average value ρ in the 4 tet changing with the feed rate. 1 It can be een from Fig. 7 that: v / mm min (1) When turning the aluminum rod, the average ρ will be decreaed with the increae of the feed rate; while the turning nylon rod, the average ρ increae. (2) When the feed rate i 69.5 mm/min, the average value ρ of the turning of the aluminum rod i 4.2 time of that of the turning nylon under the ame turning condition. (3) The difference of the average value of the tool vibration auto power pectral denity of the correponding two kind of turning material i reduced. When the feed rate i 273mm/min, the average value ρ of the turning nylon rod i higher than that of the aluminum rod, the ratio i Comparion of the characteritic of the two material can be drawn: The rigidity of the aluminum rod i greater than that of the nylon rod, In the turning proce, the deformation of nylon rod i larger than that of aluminum rod under the action of turning force, at the ame time, a large number of chip are eaily produced in the turning of nylon rod, chip are wrapped around the rod and tool. The vibration i not mooth, and the pectral value i increaed. The Influence of Spindle Speed on the Turning Vibration According to the tet Scheme 2, the maximum auto power pectral denity of the vibration ignal and the maximum auto power pectrum of the 4 turning of the vibration ignal are obtained, a hown in Table 3. Table 3. The maximum of auto-power pectral denity under different pindle peed. Material Aluminum rod Nylon rod ρ(1-3 m 2-3 ) n(r/min) feed 1 feed 2 feed 3 feed 4 Average

8 According to Table 3, in the ame way, draw the curve of the maximum auto power pectral denity ρ of two kind of tet piece of aluminum and nylon with the change of the pindle peed, a hown in Fig /1 m aluminum bar nylon bar n / r min Figure 8. Curve of the average value ρ in the 4 tet changing with pindle peed. From Fig. 8, we find that (1) When turning aluminum and nylon, the vibration characteritic of turning i imilar with the change of the pindle peed. With the increae of pindle peed, the maximum auto power pectral denity increae firt and then decreae. (2) When the pindle peed i le than 7r/min, the value ρ of the aluminum rod increae lowly, while the value ρ of nylon rod increae rapidly, and the value ρ of the aluminum rod i more than that of the aluminum rod; When the pindle peed i more than 7r/min, ρ value decreaed, and the correponding average value of the lat two kind of turning material tended to be conitent. (3) When n=6r/min in figure 8, the average value of ρ i 4.2 time of the turning of the nylon rod. When n=7r/min, the average ρ of the turning nylon rod i 1.28 time of the turning aluminum rod. When the pindle peed reache n=1r/min, Turning vibration i mooth, ρ value are rapidly reduced to zero. CONCLUSIONS (1) Keep the pindle peed and the turning depth i contant, When the aluminum rod i turned at lower feed rate, the vibration of the tool urface i tronger than that of the nylon rod, The average value ρ of the maximum auto power pectrum denity of the tool urface obtained from the 4 turning of the aluminum rod i 4.2 time of that of the nylon rod; (2) When the feed rate increae, average ρ reduce when turning rod nylon rod while turning the nylon rod increae, the average value of ρ in turning nylon i higher than that of turning aluminum rod at the higher peed; (3) Keep feeding rate and turning depth, with the increae of pindle peed, the maximum auto power pectral denity of turning the two kind of turning material 1163

9 increae firt and then decreae. When the peed i le than 7r/min, the ρ value of the aluminum rod increae lowly, while the ρ value of the nylon material increae rapidly, and the aluminum rod i more than the aluminum rod; When the pindle peed i more than 7r/min, the ρ value i reduced, the correponding average ρ of the lat two kind of turning material tend to be conitent. (4) When the pindle peed i low, the vibration of turning the aluminum rod i more evere than that of the nylon rod. When n=6r/min, the average value of ρ i 4.2 time of the turning of the nylon rod; When n=7r/min, the average ρ of the turning nylon rod i 1.28 time of the turning aluminum rod, when the pindle peed n=1r/min, the turning vibration i table, and the ρ value i reduced to zero. ACKNOWLEDGEMENT The author gratefully acknowledge the financial upport from the National Natural Science Foundation of China (No ), and the Priority Academic Program Development of Jiang-u Higher Education Intituti on, and the Xuzhou Plan Project of Science and Technology. REFERENCES [1] Ahmed Syed Adnan, Sathyan Subbiah. Experimental invetigation of tranvere vibration-aited orthogonal cutting of AL-224[J]. International Journal of Machine Tool & Manufacture.5 (21) [2] W.M. LIU,X. AI, J. ZHAO, B.L. WANG. Study on tool life in turning 3M ultra high trength teel with Al2O3 - baed ceramic cutting tool [J]. Manufacturing Technology & Machine Tool.(212) [3] Y. F. GE, J.H. XU, H. YANG. Experiment of ultra-preciion turning of SiCp/Al compoite[j]. Optic and P reciion Engineering, 17(29) [4] X.C. ZHU, L.P. SHEN. An Experimental Reearch on the Surface Roughne by Dry Cutting of Hardened Steel SKD11[J]. Manufacturing Technology & Machine Tool. (29) [5] X. Ding, M. Rahman. A tudy of the performance of cutting polycrytalline Al 661T6 with ingle crytalline diamond micro-tool[j]. Preciion Engineering.36 (212) [6] Jeong-Du Kim and Eun-Sang Lee. A Study of Ultraonic Vibration Cutting of Carbon Fibre Reinforced Platic[J]. Int J Adv Manuf Technol. 12 (1996) [7] M. Zhou, B.K.A. Ngoi, M.N. Yuoff, X.J. Wang. Tool wear and urface finih in diamond cutting of optical gla [J]. Journal of Material Proceing Technology.174 (26) [8] Z.T. ZHOU, L.J. MA, Z.S. CHEN, A.B. YU. Experimental tudy on material removal in turning of fluorophlogopite[j]. Ordnance Material Science and Engineering. 31(28) [9] Y. Peng & Z. Liang & Y. Wu & Y. Guo & C. Wang. Effect of vibration on urface and tool wear in ultraonic vibration-aited cratching of brittle material[j]. Int J Adv Manuf Technol.59 (212) [1] M. Zhou,X.J. Wang, B.K.A. Ngoi, J.G.K. Gan. Brittle ductile tranition in the diamond cutting of glae with the aid of ultraonic vibration[j]. Journal of Material Proceing Technology. 121 (22)