MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

ABSTRACT:
In this work, the modal analysis of SANDVIK PDJN/L cutting tool has been done
theoretically and numerically by using ANSYS, by assuming both tool holder and insert as a
single body and also as a cantilever beam.

Since the study of modal analysis is very important from different machine conditions point
of view and vibration chatters the modal analysis has been done.

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

1. INTRODUCTION
Turning machine vibration is an old problem on manufacturing processes. Unless avoided,
vibrations may cause large dynamic loads damaging the machine spindle, cutting tool, or
work-piece and leave behind a poor surface finish.
Cutting is a complicated process where in performance depends upon a number of cutting and
tooling conditions. Today the standard procedure to avoid vibration during machining is by
careful planning of the cutting parameters. Machining vibration exists throughout the cutting
process. While influenced by many sources, such as machine structure, tool type, work
material, etc., the composition of the machining vibration is complicated.
However, at least two types of vibrations, forced vibration and self excited vibration, were
identified as machining vibrations. Forced vibration is a result of certain periodical forces that
exist within the machine. The source of these forces can be bad gear drives, unbalanced
machine-tool components, misalignment, or motors and pumps, etc. Self-excited vibration,
which is also known as chatter, is caused by the interaction of the chip removal process and
the structure of the machine tool, which results in disturbances in the cutting zone. Chatter
always indicates defects on the machined surface; vibration especially self-excited vibration
is associated with the machined surface roughness [1].

Machining and vibration measuring are invariably accompanied by relative vibration

between work piece and tool. These vibrations are due to one or more of the following
causes:
1) In homogeneities in the work piece material.
2) Variation of chip cross section.
3) Disturbances in the work piece or tool drivers.
4) Dynamic load generated by acceleration of massive moving components.
5) Vibration transmitted from the environment.

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

2. MODAL ANALYSIS:
The modal analysis is carried out to find the natural frequency of a system or a single
component, it gives range of natural frequencies.
The importance of modal analysis is it gives mode shapes that, the structural behavior of the
component when it vibrates under external load and it is important to know the natural
frequencies because , if it matches with the forcing frequency the component or system may
be damaged so to avoid that condition the modal analysis is necessary to carry out.
The modal analysis can be obtained by different methods by using impact hammer or with
theoretical calculations, but if the system becomes complex, and if the forcing conditions
become non linear , then statistical tools or vibration power spectral density obtain from
machining process need to be taken as a input in order to determine natural frequency of the
cutting tool or system, with the advent of new finite element methods with the pre stressed
mode , it has become easier to find natural frequency of component or system.
In this report, first the FEM modal analysis is done by using ANSYS and then the theoretical
natural frequency is found out using stiffness formula.

Assumptions made:
Both insert and tool holder considered as a single component.
The tool and insert material are same that is steel with elastic modulus 210MPa.
No external forces are acting on it.

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

3.ANALYSIS & RESULTS:

Cutting tool:
The cutting tool is selected from SANDVIK CORMONT catalogue which is used for turning
in high speed machining.
PJDNL 2525 M 15
Which defines its feature as left hand cutting tool, 25X25, 150 length in millimeters
And the tool is made of steel. ANSYS R14.5 is used for analysis.[2]

The STEP file is obtained from 3d catalouge and the tool geometry has been modified using
CATIA V5, by applying material properties to it and some geometric correction such as
Boolean assembly is done in order to increase the accuracy of results.

After geometric corrections, the geometric model is imported to ANSYS workbench in modal
analysis tool box.
After importing model, analysis is done by applying these steps:
1) First the engineering data required for model is updated.

FIGURE 3.1 IMPORTED 3D MODEL

2) The geometry data for the model will be edited and updated,

FIGURE 3.2 GEOMETRY CORRECTION

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

3) Then in model, the left side of model is treated as fixed support since it will be holded
in turret and since it’s assumed as cantilever beam it will be fixed at one end.

FIGURE 3.3 WITH FIXED SUPPORT

4) Then appropriate meshing will be done.

FIGURE 3.4 MESHING

5) Then using solver the solution will be done giving the number of natural frequencies
required.

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

Below figures shows modal shapes, here i have done it for 6 modes

FIGURE 3.5 FIRST MODE

FIGURE 3.6 SIXTH MODE

FIGURE 3.7 SECOND MODE

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

FIGURE 3.8 THIRD MODE

FIGURE3.9 FOURTH MODE

FIGURE 3.10 FIFTH MODE

FIGURE 3.11 OVERALL FREQUENCY RANGE

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

Theoritical solution:
Now the FEM solution is validated by using theoretical calculations using beam theory and
stiffness calculations
The theoretical formula for stiffness of cantilever beam is given by

3𝐸𝐼
𝐾= …………..1
𝐿3
Where, K= stiffness in N/m
E= Youngs modulus in N/m^2
I= Moment of inertia in Kg-m^2
L= Length of cantilever beam in Meters

And from stiffness the natural frequency can be found using

1
𝜔𝑛 =2П √𝐾/𝑀………….2
Where, K= stiffness in N/m
M= Mass in Kg.

E= Young’s modulus of steel 210 GPa.

Moment of Inertia = 0.001 Kg-m^2
And the mass for the geometry of tool is obtained as .707 Kg calculated using CATIA v5
By using formulae 1 and 2 it has been found that the natural frequency is 81.7 KHz.

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 MODAL ANALYSIS OF SANDVIK PDJN/L CUTTING TOOL

4.CONCLUSION:
Modal analysis is done using ANSYS 14.5, and it is compared with the theoretical
calculations using beam theory, but the natural frequency of cutting tool has been nearly ten
times of FEM analysed value. It may be due to assumptions taken into consideration.

References:
1) Dr.Bashar A.Bedaiwi , Experimental and Numerical study of Turning Cutting tools
Random vibration towards mitigation, Journal of Engineering and Development, Vol. 17,
No.3, August 2013, ISSN 1813- 7822
2) PUPĂZĂ CRISTINA, TĂNASE IOAN, MARDARI VIOREL, COTESCU
ALEXANDRU, Modal Analysis of a Turning Tool System, Proceedings of the 1st WSEAS
International Conference on VISUALIZATION, IMAGING and SIMULATION (VIS'08)
3) SANDVIK CORMONT E CATALOUGE.

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