Studies on cutting responses in boring process using impact dampers

Abstract

During the last few years, the prediction and optimization of cutting newlineprocess parameters in various machining processes have received more newlineattention than ever before, from research community all over the world. The newlinesoft computing techniques which are used for predicting and optimizing the newlinecutting process parameters offer a number of advantages over the traditional newlinenumerical methods. In the present investigation, the effect of the cutting newlineprocess parameters in boring tool with and without impact dampers was newlinestudied. The impact dampers made up of Copper, Phosphor Bronze, Brass, newlineGun Metal, EN8, Cast Iron and Aluminium were used and the cutting newlineparameters and their effect on cutting responses in boring tool with and newlinewithout dampers were studied experimentally. Then the experimental values newlineobtained were modeled for prediction with the help of Artificial Neural newlineNetwork (ANN). The optimum set of readings was determined using newlineResponse Surface Methodology (RSM) and the interaction effect cutting newlineparameter on cutting responses were discussed using Analysis of Variance newline(ANOVA) method. The impact hammer test was conducted to determine the natural newlinefrequency of the boring tool. As per ISO standards the boring tool with a newlinelength of 250 mm and 18 mm height was used to bore the workpiece of Mild newlinesteel without the attachment of the damper. The Displacement of tool newline(amplitude of vibration in horizontal direction), Cutting Temperature and newlineTool wear were determined for the speeds of 300, 400 and 500 rpm and for the depth of cuts of 0.25, 0.50 and 0.75mm where a constant feed rate of 0.07 newlinem/min was given. Then the tool was attached with impact dampers with a newlinediameter of 9 mm and a height of 8 mm. The dampers of Copper, Phosphor newlineBronze, Gun Metal, Cast Iron, Brass, EN8 and Aluminium were equipped newlinewith the boring tool at a distance of 44 mm, 54 mm and 64 mm respectively newlineand the impact hammer test was carried out for each position to determine the newlinenatural frequency of the boring tool. newline