1

Introduction

Machining processes involve removal of material from workpieces whatever which mechanism material removal is used. Then machining as a manufacturing process is evaluated by two main aspects; productivity and product quality. Usually the productivity of machining processes is measured by material removal rate (MRR), and product quality is measured by surface roughness. To achieve these main claims of machining, there are many constrains. One of the major constrains is mechanical vibrations that aects the whole MFTW (Machine-Fixture-Tool-Workpiece) system. Metal cutting processes can entail three dierent types of mechanical vibrations that arise due to the lack of dynamic stiness of one or several elements of the system composed by the machinetool,thetoolholder,the cutting tool and the workpiece material.These three types of vibrations are known as free vibrations,forced vibrations and self-excited vibrations. [2] Although the other machining processes such as milling, turning and drilling have been studied relatively broader and deeper, there were only a few attempts to model the cutting forces and stability in boring [1]. The enlargement of holes is achieved via boring operations. The hole diameter is either enlarged with a single insert attached to a long boring bar, or with a boring head which has a diameter equal to the diameter of the hole to be enlarged. Long boring bars statically and dynamically deform under the cutting forces during boring operations. Excessive static deections may violate the dimensional tolerance of the hole, and vibrations may lead to poor surface, short tool life and chipping of the tool. The problem of vibration becomes more signicant when a exible tool is used,as in the case of internal turning operations. [4]. Thats why boring process is a very specic case for machine tool chatter that need a more comprehensive work. Due to the insucient rigidity of boring bars, chatter is more likely to occur in boring than in any other machining operation, which results in a poor surface quality, shorter tool life and limited production rate. Extensive investigations have been carried out to avoid chatter vibrations. Several types of vibration dampers have been suggested by previous investigators. However, due to the complexity, high expenses, and size limitations of such dampers they have found only limited practical applications. More satisfactory results can still be attained by an adequate selection of cutting conditions as was proved by previous investigations carried out into chatter in turning. [3] According to what is mentioned before, this thesis aims at improvement of boring bar dynamic properties in order to supress chatter phenomenon in the working eld of machining conditions. The next sections will clearly identify the chatter 1

phenomenon explanation, previous attempts to solve the problem in boring operations, how to measure the ability of any solution to suppress chatter, and nally this work approach to oer a new solution to the mentioned problem.

2
2.1

Explanation of Chatter Phenomenon

Arnold RN. The mechanism of tool vibration in cutting of steel. Proc. of the institution of Mechanical Engineers, 1946

The author has attained some important concepts regarding machine tool vibrations. The rst is the dierentiation between self-induced and forced excitations; that self excited vibrations results in virtue of forces derived from its own motion, while forced vibrations results essentially from an external periodic force which is quite independant of the system on which it acts, also he claries that the force producing the vibration (in case of forced vibrations) is dependant on the vibration which existed at a previous time. The pedant might claim that this is in eect of self-induced vibraiton, but mathematically it has all the characteristics of a forced vibration. The regenerative eect of previously machined surface is studied by Tobias [5] but in contradiction to Arnold he called it regenerative chatter. Another important result is the eect of tool wear on self excited vibrations, which have a non linear relation at low values of wear till the amplitude of vibration jumps to a higher level at a certain wear value and stabilizes for the increasing wear. This meansas explained by M.A.Salam [6] that the rst stage of ank war produces high damping values at which self excited vibrations do not exist, but after natural wear generation for a certain extent the the resulting damping coecient inverts into negative value due to the decreasing eect of damping related to ank wear. Also the author explained the change of wear eect with respect to cutting speed, as he compared the wear at width with the wavelength of the undergoing undulations generated by previous cutts, so when the cutting speed is varied the wavelength is also varied with respect to a constant wear at, thereby the cutting prole and the overlapping changes by changing cutting velocity. He explained the initiation of the self-induced vibrations as due to the negative ingradient of the force-vibration speed relation that induces chatter vibrations in the vertical direction (cutting speed direction). Also He checked for the limiting cases of the vibration amplitudes, and he found that at the case of equal values of the cutting speed w.r.t the vibrational velocity, the dierential between them may turn into negative value which gives a damping eect that controls the self-induced vibrations amplitude. 2

The negative gradient of force-velocity is also explained as the relation between plastic deformations and cutting speed. The plastic deformations occurs during cutting relates to the forces of the cutting process, so as these deformations are higher at lower speeds (due to element of time necessary for plastically deforming of crystal structure), thereby the forces are higher at lower speeds, he also checked if this is true in case of rapid uctuations of tool vibration. Finally , he shows that the forced vibrations are initiated due to passing on a wavy surface due to previous cuts generated due to self excited vibrations, therefore these forced vibrations tend to have a very high amplitude because the system is excited by the frequency of the undulations found on the previously machined surface which is very near to system natural frequencies.

Bibliography
[1] F Atabey, I Lazoglu, and Y Altintas. Mechanics of boring processespart i. International Journal of Machine Tools and Manufacture, 43(5):463476, 2003. [2] Quintana G. and Ciurana J. Chatter in machining processes: A review. 51(5), 2011. [3] Abu-Aesh M.A. An investigation into the self-excited vibrations of boring bars on a centre lathe. Technical report, 1982. [4] Miguelez M.H, Rubio L., Loya J.A., and Fernandez-Saez J. Improvement of chatter stability in boring operations with passive vibration absorbers. 2010. [5] Tobias SA. Machine-tool vibration. Blackie and Son Limited, 1965. [6] M. Abdel Salam. An investigation into the cutting prrocess dynamics in turning. Technical report, Cairo,, 1987.