Machining-3

Cutting Fluid and Chatter

ME 338: Manufacturing Processes II

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton

Cutting Fluids - Effects

Reduce friction and wear
improve tool life, surface finish

Cool cutting zone

reduce temperature and distortion

Wash chips away

Prevent corrosion
Reduces forces and energy consumption

Cutting Fluids - Types

Water based
contain salts or
soluble oils

Mineral-oil based
Synthetic

Bio-degradable
Bio-resistant
Soaps
Defoamers
Sulphur
Chlorinated

Cutting Fluids Application Methods

Brush
manual

Mist
mostly water based coolants

Flood

Coolant or Lubricant?

Temperature
Cutting speed
Type of machining operation
Method of application
brush (manual)
mist
flood

Vibration
Forced
periodic applied force
from a motor or gear drive

Self-excited
interaction of dynamics of chip removal process
and structural dynamics of machine tool

Chatter
Results from vibration
Tool bounces in and out of the workpiece

Glacial Chatter

Chatter Types
Regenerative (f < 1000 Hz)
when a surface undulation
previously produced causes a
cutting force variation

Coupling (f < 1000 Hz)

two modes of tool or machine
vibration are coupled (x and y
directions)

Chatter Types
Self-excited vibration (1000 < f < 10,000 Hz)
negative slope of the shear-stress vs. temperature
(t vs. q) relationship
force components provide positive instead of
negative damping

10

Vibration Elimination

Stiffer machines
Tuned dampers
Active control
Support workpiece rigidly
Minimize cutter overhang
Modify tool and cutter geometry
Change process parameters
speed, feed, depth of cut, cutting fluid

11

Case study of vibration control in High

Speed Micromachining

ME 338: Manufacturing Processes II

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton

Best Configuration selection

Goal: To find most stiff configuration
Approach:Model : Machine base with frame
BC: Bottom of base fixed
Load : Force of magnitude 60 N applied
at the middle of bridge

components

Ribs

No ribs

No slot

Configuration-1

Configuration-2

Slot

Configuration-3

Configuration-4

Different configurations

Max def
Deformation(m)

1.00E-07

def_x

8.00E-08

def_y

6.00E-08

def_z

4.00E-08
2.00E-08
0.00E+00
1

Configuration no.

Static deformation in machine base and machine frame

Configuration 3&4 better

13

Modes of High Speed Micromachine Tool

ME 338: Manufacturing Processes II

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton

Frequency(Hz)

3600
3300
3000
2700
2400
2100
1800
1500
1200
900
600
300
0

e) 18th mode (2408 Hz)

prototype-I

f) 20th mode (2662 Hz)

with ribs
no ribs

Prototype-II frequency
more than prototype-I
No ribs case higher
frequency more than
with ribs case
first 6 modes critical
With ribs case better
than others, supported by
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
frequency response curve
Mode no.
15

Frequency Response Analysis

ME 338: Manufacturing Processes II

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton

Stability Lobes (Process Controlled)

Axial depth of chip width

ME 338: Manufacturing Processes II

Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton

Summary
Chip formation process
Cutting fluids
Vibration and chatter

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