30120140506002

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),

ISSN 0976 – 6359(Online), Volume 5, Issue 6, June (2014), pp. 14-27 © IAEME

14

ANALYSIS AND MODELING OF SINGLE POINT CUTTING

(HSS MATERIAL) TOOL WITH HELP OF ANSYS FOR OPTIMIZATION OF

(TRANSIENT) VIBRATION PARAMETERS

Prabhat Kumar Sinha, Rajneesh Pandey*, Vijay Kumar yadav

Department of Mechanical Engineering, Shepherd School of Engineering & Technology, Allahabad

ABSTRACT

The purpose of this article is to study the change of vibration on lathe machine by the change

of tool material. Industrial vibration on analysis is a measurement tool used to identify, predict and

prevent failure in any rotating machinery. By the vibration analysis on any mechanical component

will improve the reliability of machine and lead to better machine efficiency and reduce down time

for eliminating electrical and mechanical failure. Machining and measuring operations are invariably

accompanied by relative vibration between work piece and tool. The main cause of vibration is as

follows: Unbalance forces in the machine: these forces are produced from within itself. Dry friction

between the two mating surfaces: this produces what are known as self excited vibration. The effect

of vibration is excessive stresses, undesirable noise, looseness of part and partial or complete failure

of parts. in spite of these harmful effects the vibration phenomena does have some uses also , e.g in

musical instrument ,vibrating screens , shakers stress reliving.

Keywords: Lathe Machine, hss Tool, Mild Steel Work Material, Ansys, Vibration Parameter

(Temperature, Pressure).

INTRODUCTION

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 drives;

(4) Dynamic loads generated by acceleration/deceleration of massive moving components;

INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING

AND TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online)

Volume 5, Issue 6, June (2014), pp. 14-27

© IAEME: www.iaeme.com/ijmet.asp

Journal Impact Factor (2014): 7.5377 (Calculated by GISI)

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IJMET

© I A E M E



15

(5) Vibration transmitted from the environment;

(6) Self-excited vibration generated by the cutting process or by friction (machine-tool chatter).

The tolerable level of relative vibration between tool and work piece, i.e., the maximum

amplitude and to some extent the frequency is determined by the required surface finish and

machining accuracy as well as by detrimental effects of the vibration on tool life and by the noise

which is frequently generated.

ANALYSIS OF MACHINE TOOL VIBRATION BY ANASYS METHOD

Trainsents Vibrations can be analyzed by developing software’s. In this paper we design tool

of hss material has comparatively better resistance to heat and wear, and work piece used of mild

steel all the data are taken from standard researches paper the and input values are used analysis

vibration through ansys method . we know that vibration is directly factor of temperature so in this

analysis we find transient analysis, geometric analysis ,mesh analysis on different vibration

producing parameters like pressure and temperature and by taking analysis on different pressures all

are shown given below.

Tool specification

Back Rake angle 12degree

Side Rake angle 12degree

End relief angle 10degree

End cutting edge angle 30degree

Side cutting Edge angle 15degree

Nose Radius 0.8mm

Contents

• Unit



16

• Model (A4) o Geometry

� Part 1

o Coordinate Systems

o Mesh

o Transient Analysis (A5) � Analysis Settings

� Loads

� Solution (A6)

� Solution Information

� Results

� Stress Tool

� Safety Factor

� Stress Tool 2

� Safety Factor

� Minimum Principal Elastic Strain

• Material Data o High speed Steell

Units

TABLE 1

Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius

Angle Degrees

Rotational Velocity rad/s

Temperature Celsius

Model (A4)

Geometry

TABLE 2

Model (A4) > Geometry

Object Name Geometry

State Fully Defined

Definition

Source C:\Users\vijay\Desktop\tool.igs

Type Iges

Length Unit Meters

Element Control Program Controlled

Display Style Part Color

Bounding Box

Length X 3.0001e-002 m

Length Y 8.6052e-002 m

Length Z 3.7476e-002 m

Properties

Volume 6.9165e-005 m³



17

Mass 0.54295 kg

Scale Factor Value 1.

Statistics

Bodies 1

Active Bodies 1

Nodes 4418

Elements 854

Mesh Metric None

Preferences

Import Solid Bodies Yes

Import Surface Bodies Yes

Import Line Bodies No

Parameter Processing Yes

Personal Parameter Key DS

CAD Attribute Transfer No

Named Selection Processing No

Material Properties Transfer No

CAD Associativity Yes

Import Coordinate Systems No

Reader Save Part File No

Import Using Instances Yes

Do Smart Update No

Attach File Via Temp File Yes

Temporary Directory C:\Users\vijay\AppData\Local\Temp

Analysis Type 3-D

Mixed Import Resolution None

Enclosure and Symmetry Processing Yes

TABLE 3

Model (A4) > Geometry > Parts

Object Name Part 1

State Meshed

Graphics Properties

Visible Yes

Transparency 1

Definition

Suppressed No

Stiffness Behavior Flexible

Coordinate System Default Coordinate System

Reference Temperature By Environment

Material

Assignment Structural Steel

Nonlinear Effects Yes

Thermal Strain Effects Yes



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Bounding Box

Length X 3.0001e-002 m

Length Y 8.6052e-002 m

Length Z 3.7476e-002 m

Properties

Volume 6.9165e-005 m³

Mass 0.54295 kg

Centroid X 1.4936e-002 m

Centroid Y 2.6577e-002 m

Centroid Z 1.6318e-002 m

Moment of Inertia Ip1 3.1446e-004 kg·m²



Statistics

Nodes 4418

Elements 854

Mesh Metric None

Coordinate Systems

TABLE 4

Model (A4) > Coordinate Systems > Coordinate System

Object Name Global Coordinate System

State Fully Defined

Definition

Type Cartesian

Ansys System Number 0.

Origin

Origin X 0. m

Origin Y 0. m

Origin Z 0. m

Directional Vectors

X Axis Data [ 1. 0. 0. ]

Y Axis Data [ 0. 1. 0. ]

Z Axis Data [ 0. 0. 1. ]

Mesh

TABLE 5

Model (A4) > Mesh

Object Name Mesh

State Solved

Defaults

Physics Preference Mechanical

Relevance 0

Sizing



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Use Advanced Size Function Off

Relevance Center Coarse

Element Size Default

Initial Size Seed Active Assembly

Smoothing Medium

Transition Fast

Span Angle Center Coarse

Minimum Edge Length 1.7765e-003 m

Inflation

Use Automatic Tet Inflation None

Inflation Option Smooth Transition

Transition Ratio 0.272

Maximum Layers 5

Growth Rate 1.2

Inflation Algorithm Pre

View Advanced Options No

Advanced

Shape Checking Standard Mechanical

Element Midside Nodes Program Controlled

Straight Sided Elements No

Number of Retries Default (4)

Rigid Body Behavior Dimensionally Reduced

Mesh Morphing Disabled

Pinch

Pinch Tolerance Please Define

Generate on Refresh No

Statistics

Nodes 4418

Elements 854

Mesh Metric None

Transient Analysis (A5)

TABLE 6

Model (A4) > Analysis

Object Name Static Structural (A5)

State Solved

Definition

Physics Type Structural

Analysis Type Static Structural

Solver Target ANSYS Mechanical

Options

Environment Temperature 22. °C

Generate Input Only No



20

TABLE 7

Model (A4) > Trasient Analysis (A5) > Analysis Settings

Object Name Analysis Settings

State Fully Defined

Step Controls

Number Of Steps 1.

Current Step Number 1.

Step End Time 1. s

Auto Time Stepping Program Controlled

Solver Controls

Solver Type Program Controlled

Weak Springs Program Controlled

Large Deflection Off

Inertia Relief Off

Nonlinear Controls

Force Convergence Program Controlled

Moment Convergence Program Controlled

Displacement Convergence Program Controlled

Rotation Convergence Program Controlled

Line Search Program Controlled

Output Controls

Calculate Stress Yes

Calculate Strain Yes

Calculate Results At All Time Points

Analysis Data Management

Solver Files Directory C:\Users\vijay\Documents\tool static_files\dp0\SYS\MECH\

Future Analysis None

Scratch Solver Files Directory

Save ANSYS db No

Delete Unneeded Files Yes

Nonlinear Solution No

Solver Units Active System

Solver Unit System Mks

TABLE 8

Model (A4) > Transient Analysis (A5) > Loads

Object Name Fixed

Support

Fixed Support

2 Pressure Pressure 2 Pressure 3

State Fully Defined

Scope

Scoping

Method Geometry Selection

Geometry 1 Face

Definition



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Type Fixed Support Pressure

Suppressed No

Define By Normal To

Magnitude 2000. Pa

(ramped)

1100. Pa

(ramped)

1200. Pa

(ramped)

FIGURE 1

Model (A4) > Transient Analysis (A5) > Pressure

Solution (A6)

TABLE 9

Model (A4) > Transient Analysis (A5) > Solution

Object Name Solution (A6)

State Solved

Adaptive Mesh Refinement

Max Refinement Loops 1.

Refinement Depth 2.

TABLE 10

Model (A4) > Transient Analysis (A5) > Solution (A6) > Solution Information

Object Name Solution Information

State Solved

Solution Information

Solution Output Solver Output

Newton-Raphson Residuals 0

Update Interval 2.5 s

Display Points All



22

TABLE 11

Model (A4) > Transient Analysis (A5) > Solution (A6) > Results

Object Name Total

Deformation Shear Elastic Strain Equivalent Stress

State Solved

Scope

Scoping Method Geometry Selection

Geometry All Bodies

Definition

Type Total

Deformation Shear Elastic Strain

Equivalent (von-Mises)

Stress

By Time

Display Time Last

Calculate Time

History Yes

Identifier

Orientation XY Plane

Coordinate System Global Coordinate

System

Use Average Yes

Results

Minimum 0. m -1.2165e-007 m/m 23.598 Pa

Maximum 2.7172e-009 m 3.6283e-008 m/m 46326 Pa

Information

Time 1. s

Load Step 1

Substep 1

Iteration Number 1



23

TABLE 12

Model (A4) > Transient Analysis (A5) > Solution (A6) > Stress Safety Tools

Object Name Stress Tool

State Solved

Definition

Theory Max Shear Stress

Factor 0.5

Stress Limit Type Tensile Yield Per Material

TABLE 13

Model (A4) > Transient Analysis (A5) > Solution (A6) > Stress Tool > Results

Object Name Safety Factor

State Solved

Scope


Geometry All Bodies

Definition

Type Safety Factor

By Time

Display Time Last

Calculate Time History Yes

Use Average Yes

Identifier

Results

Minimum > 10

Information

Time 1. s

Load Step 1

Substep 1

Iteration Number 1

TABLE 14

Model (A4) > Transient analysis (A5) > Solution (A6) > Stress Safety Tools

Object Name Stress Tool 2

State Solved

Definition

Theory Max Tensile Stress

Stress Limit Type Tensile Yield Per Material



24

TABLE 15

Model (A4) > Transient Analysis (A5) > Solution (A6) > Stress Tool 2 > Results

Object Name Safety Factor

State Solved

Scope


Geometry All Bodies

Definition

Type Safety Factor

By Time

Display Time Last


Use Average Yes

Identifier

Results

Minimum > 10

Information

Time 1. s

Load Step 1

Substep 1

Iteration Number 1

TABLE 16

Model (A4) Transient Analysis (A5) > Solution (A6) > Results

Object Name Minimum Principal Elastic Strain

State Solved

Scope


Geometry All Bodies

Definition

Type Minimum Principal Elastic Strain

By Time

Display Time Last


Use Average Yes

Identifier

Results

Minimum -2.1986e-007 m/m

Maximum -8.5164e-011 m/m

Information

Time 1. s

Load Step 1

Substep 1

Iteration Number 1



25

Material Data

High Speed Steel

TABLE 17

High Speed Steel > Constants

Density 7850 kg m^-3

Coefficient of Thermal Expansion 1.2e-005 C^-1

Specific Heat 434 J kg^-1 C^-1

Thermal Conductivity 60.5 W m^-1 C^-1

Resistivity 1.7e-007 ohm m

TABLE 18

High Speed Steel > Compressive Ultimate Strength

Compressive Ultimate Strength Pa

0

TABLE 19

High Speed Steel > Compressive Yield Strength

Compressive Yield Strength Pa

4.5e+008

TABLE 20

High Speed Steel > Tensile Yield Strength

Tensile Yield Strength Pa

4.5e+008

TABLE 21

High Speed Steel > Tensile Ultimate Strength

Tensile Ultimate Strength Pa

4.6e+008

TABLE 22

Transient Analysis > Alternating Stress

Alternating Stress Pa Cycles Mean Stress Pa

3.999e+009 10 0

2.827e+009 20 0

1.896e+009 50 0

1.413e+009 100 0

1.069e+009 200 0

4.41e+008 2000 0

2.62e+008 10000 0

2.14e+008 20000 0

1.38e+008 1.e+005 0

1.14e+008 2.e+005 0

8.62e+007 1.e+006 0



26

TABLE 23

High Speed Steel > Strain-Life Parameters

Strength

Coefficient Pa

Strength

Exponent

Ductility

Coefficient

Ductility

Exponent

Cyclic Strength

Coefficient Pa

Cyclic Strain

Hardening

Exponent

9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2

TABLE 24

High Speed Steel > Relative Permeability

Relative Permeability

10000

TABLE 25

High Speed Steel > Isotropic Elasticity

Temperature C Young's Modulus Pa Poisson's Ratio

2.e+011 0.3

7. CONCLUSION

Thus we have seen the various aspects of machine tools vibrations and their effects. It has

been seen that the effect of vibrations can be disastrous. It may lead to undesirable results on the

work piece. Hence to minimize the vibrations in the tools a lot of research and study has been done.

This has drastically changed the machine efficiency and also minimized the harmful effects of

vibrations on the workers. With the advent of technology, software’s and highly precision

instruments have been developed to measure and analyze the vibrations caused in tools and to bring

up solutions quickly. It has become easier to evaluate the unwanted motions at different parts of a

machine and to rectify it. Hence it may be concluded that a machine tool should be designed keeping

all kinds of errors in mind.

8. REFERENCES

8.1 BOOKS

[1] Harris' Shock and Vibration Handbook 6th.Ed.(2009)

[2] James L. Taylor, The Vibration Analysis Handbook

[3] E.I. Rivin, Machine Tool Vibration

[4] MECHANICAL VIBRATION BY G.K. GROVER 8TH

EDITION

[5] Mechanical vibration by vp Singh.

8.2 JOURNALS AND TECHNICAL PAPERS

[6] Eiji Nabata, Yuji Terasaka Jig Rigidity Evaluation Technology by Vibration Analysis, VOL.

52, 2006.

[7] S. Braun Adaptronic Vibration Damping for Machine Tools.

[8] S.Y. Lin, Y.C. Fang, C.W. Huang, Improvement strategy for machine tool vibration induced

from the movement of a counterweight during machining process, February 2008.



27

[9] Kourosh Tatar, Per Gren, Measurement of milling tool vibrations during cutting using laser

vibrometry.

[10] John G .Cherng, Mahmut Eksioglu, Kemal Kızılaslan, Vibration reduction of pneumatic

percussive rivet tools: Mechanical and ergonomic re-design approaches.

[11] Effect of cutting parameters on surface roughness and cutting forces in turning mild steel by

research journal of recents sciences vol.1(10), 19-26, October (2012) for standard design

parameters for tool design.

[12] Optimization of cutting parameters on mild steel with hss & cemented carbide tipped tools

using Ann by Proff A.V.N .L SHARMA(2006).

[13] Shaw metal cutting principle, Oxford University press (2006).

[14] Basic machining refrenance handbook, industrial press (2001).

[15] Analysis of cutting force during milling with regards to dependency on the penetration angle

(2009).

[16] Patel K. Batish and Bhattacharya A optimization of t surface roughness in an end milling

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[17] Mile j.R-square, Adjusted R-squared, Encyclopedia of stastican Behavioral science, john

Wiley and son’s ltd (2005).

[18] Ricci L and Martinez R, Adjusted R2 –Type measure for tweedy model, computational

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[19] Sharma V.S,, Sharma S.K, and Sharma A.K, cutting wear estimation for turning, journal of

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[20] Montgomery, D.C, Design and Analysis of experiment, John Wiley and sons (2001)

[21] Das M.N and Girl N.C, Design and analysis of experiment second New age international

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[22] Rodrigues L.I.R, Kantharaj B, and Murthy B.R.N Effect of cutting Parameters on surface

roughness and cutting forces in turning mild steel (2012).

[23] Prabhat Kumar Sinha, Rakesh Kumar Maurya, Rajneeshpandey and Vijay Kumar Yadav,

“Analysis of Residual Stresses and Distortions in Tig-Welded Stainless Steel Pipe”,

International Journal of Mechanical Engineering & Technology (IJMET), Volume 5, Issue 5,

2014, pp. 13 - 27, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.

[24] Prabhat Kumar Sinha, Rakesh Kumar Maurya, Rajneeshpandey and Vijay Kumar Yadav,

“Analysis for Free Vibration of Laminated Composite & Sandwich Plates with the Help of

Euler-Lagrange Equation Based on First Order Shear Deformation Theory, Formulations and

Solution to the Natural Frequency & Compare to Obtained Results”, International Journal of

Mechanical Engineering & Technology (IJMET), Volume 5, Issue 5, 2014, pp. 45 - 53,

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[25] Ganesan.H and Mohankumar.G, “Study on Optimization of Machining Parameters in

Turning Process using Evolutionary Algorithm with Experimental Verification”,

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[26] Pravin Kumar.S, Venkatakrishnan.R and Vignesh Babu.S, “Process Failure Mode and Effect

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