SUPPRESSION OF BORING BAR VIBRATIONS

Objective of this thesis is to:

Develop a background on the phenomenon.

Observe the chatter phenomena in the boring process
Determine the conditions and parameters that affect the existence of chatter.
Design a tool for suppressing chatter
Derive of a mathematical model[or use of an existing one] to explain the chatter
behavior and its suppression
Perform experiments to observe how would the new design affects the chatter
phenomena
Verification of the experimental results with the mathematical model

Plan of Work
1. Develop a background on the chatter behavior and its mathematical modeling
References:
o PhD thesis of Dr.Moh.Abdel Salam,
o Papers for Merrit, Tobias, Altintas,etc,
o Manufacturing Automation book for Altintas.
Disciplines:
o Vibrations (Random and Non Linear)
o Theory of Metal Cutting
o Self excited vibrations on structures
o Control of self excited vibrations
Must come up with the basic mathematical model for the boring process.

Milestone1: Literature survey and Mathematical formulas to use, and different

theories explaining the same behavior.
Milestone2: Statement of the problem, research objective and research frame and
limitations
2. New design proposal
W/p supported boring bar idea.
Design should comply with
Higher system rigidity
Fixation on the center lathe.
Machining conditions

Milestone3: Finalized design ready to be manufactured and implemented.

3. Pilot Study
Previous experiences in addressing the same problem
i. M.Sc of Dr. Abu Aesh, M.Sc of Dr. Ahmed Shaaban

ii. Papers of chatter on boring bars.

iii. Two types of data should be compared; the mathematical model
and the experimental techniques.
Use of ordinary boring bar.
Observe the chatter phenomena in the boring process
Determine the conditions and parameters that affect the existence of chatter.
How the new design will improve the performance of the ordinary design.
How to use the measuring equipment for the study.

Milestone4: Relation between Chatter mathematical formula and the problem

case. Which theory is suitable for this case.
Milestone 5: Ranges of machining conditions that show the chatter problem, and
thus identifying the experiment variables and parameters.
Milestone6: Role of the new design in achieving the study objective.
4. Experimental work
Constructional modifications needed for the new design
Suitable mathematical model for the new design(either extracted or
derived)
Perform no. of experiments to determine the performance of the new
design.
Compare between the new design and the ordinary one.

Milestone7: Experimental results assuring the argument that the new design has
higher performance.
5. Verification
How do the results conform to the mathematical model used?
How can these result s explain?

Milestone8: The proposed solution is proved experimentally and verified

mathematically.
6. Conclusions
7. Recommendations