Int J Adv Manuf Technol (2014) 75:12191231
DOI 10.1007/s00170-014-6201-0
ORIGINAL ARTICLE
Investigation into effect of particle impact damping (PID)
on surface topography in boring operation
C. V. Biju & M. S. Shunmugam
Received: 10 May 2012 / Accepted: 23 July 2014 / Published online: 15 August 2014
# Springer-Verlag London 2014
Abstract This paper presents a novel method, based on the
particle impact damping (PID), for the attenuation of regener-
ative vibration in boring operation. A specially designed bor-
ing bar having a cavity near machining-end for partial filling
of spherical particles has been developed. Characteristics of
boring bar with and without PID have been found from impact
and shaker tests. After identifying appropriate particle size and
filling volume, experiments are conducted to evaluate the
performance in actual boring operations. Additional boring
experiments are also conducted to confirm the performance by
changing particle size and filling volumes. The collision of the
particles in PID is found to attenuate regenerative vibration by
the energy dissipation and thus effectively enhances stability
of the boring operation. Analysis of effect of PID on surface
topography in terms of chatter marks, surface roughness, and
roundness of bored holes shows that the proposed method
results in improvement of bore quality when compared with a
boring bar without PID. It is also established that radial
vibration of the boring bar has a significant influence on the
surface topography obtained in boring operation.
Keywords Boring operation . Regenerative vibration .
Particle impact damping . Surface topography . Chatter
marks . Surface roughness . Roundness error
1 Introduction
In general, machining operations can be classified based on
the nature of tool-work engagement into two distinct catego-
ries; namely intermittent engagement as in milling operation
C. V. Biju : M. S. Shunmugam (*)
Department of Mechanical Engineering, Indian Institute of
Technology Madras, Chennai 600036, India
e-mail: shun@iitm.ac.in
and continuous engagement as in grinding, turning, boring,
etc. Vibration is an undesirable phenomenon in any machining
operation, as it results in poor surface finish, increased form
deviation, reduced material removal rate, increased tool wear,
and higher noise level. It also affects instantaneous depth of
cut, feed-rate, shear angle, and cutting force. Vibrations in
machining process can be classified into forced and self-
excited vibrations. Forced vibration, for example, occurs due
to unbalances in forces arising from rotating members and/or
due to interrupted cutting as in milling. Tobias and Fishwick
[36] are the earlier researchers to investigate the self-excited
vibration in machining under orthogonal cutting conditions.
The previous cut resulted in a wavy surface and the dynami-
cally varying chip thickness in the subsequent pass in the
machining was shown to produce regenerative effect.
Sweeney and Tobias [32] explained that self-excited vibration,
referred to as chatter, is due to the interaction between dynam-
ic characteristics of both machine tool structure and process.
Koenigsberger and Tlusty [14] also analyzed the machine-tool
chatter and explained that the regenerative and the mode-
coupling mechanisms are the major contributors for chatter.
Among the two, former has a severe influence on the stability
of the machining process. Altintas and Weck [2] presented a
review of research work on chatter in metal cutting and
grinding. A recent review of 174 research papers on chatter
in machining process by Quintana and Ciurana [27] brings out
comphrehensively the research work carried out upto 2011.
Most of the researchers investigating the vibration effect in
interrupted cutting have considered the milling operation and
studied dynamic stability of the process. Many of the studies
involve establishing stability diagram experimentally and the
results are used for confirming the theoretically predicted
stability. The stability diagrams thus obtained are useful to
identify chatter-free zones for safe operations. Bayly et al.[4])
and Insperger et al. [13] have attempted to develop analytical
methods to predict stability in intermittent cutting like milling.
1220
Merdol and Altintas [19] have developed a virtual simulation
system incorporating vibration prediction model. It is identi-
fied that process damping has an effect on the dynamic sta-
bility and hence the effect of cutting parameters and cutting
geometry on process damping has also been studied. Patel
et al. [26] also developed an analytical model and brought out
the influence of helix-angle on the stability of milling process.
Wan et al. [39] proposed a unified stability prediction method
with multiple delays and showed that feed per tooth has great
effect in the presence of cutter run-out. Tun and Budak [37]
have shown that process conditions and tool geometry can be
appropriately selected to enhance proces damping and hence
the chatter stability. Compen et al. [6] have proposed a
milling tool with variable pitch, helix, and rake angles for
high performance milling.
In case of continuous cutting also, chatter-free machining
conditions must be identified for the machining operations
like turning, boring, etc. Takasu et al. [33] brought out the
effect of small amplitude vibration on surface roughness ob-
tained in diamond turning and suggested the methods to
improve the surface finish. Rivin and Kang [29] modeled
the work piece and cutting tool system in turning and sug-
gested a method to improve the system stability by improving
the dynamic stiffness of the tool. Lin and Hu [16] proposed a
vibration reduction system which would be triggered to sup-
press the vibration when chatter occurs. Vela-Martnez et al.
[38] developed a compliance model for turning operation by
introducing interaction between work piece and cutting tool as
lumped mass system. The effect of the dynamics of cutting
tool on the stability of process was investigated. Moradi et al.
[23] modeled orthogonal turning process as a single degree
model and proposed control strategies to suppress regenera-
tive chatter. Otto and Radons [24] have proposed an approach
involving spindle speed variation for chatter suppression in
turning operation.
The boring operations are used for enlarging or finishing
predrilled holes in cast, forged, or extruded components. The
boring bars have low inherent stiffness due to high length-to-
diameter ratio and hence are more prone to vibration. Rivin
et al. [30] modeled the cantilever boring bar and suggested
methods to improve its dynamic performance. Li et al. [15]
investigated chatter phenomenon in rotating-bar boring oper-
ations and showed that the stability limits of the system is
shifted to the higher values, by changing the speed about the
nominal speed at certain frequency. Moradi et al. [22]
modeled boring bar as Euler-Bernoulli cantilever beam and
suggested a design of tuneable vibration absorber. The pro-
posed method was analyzed for the chatter stability in boring
process. Subsequently, kesson et al. [1] focused on changing
clamping to change the dynamic properties of boring bar.
The vibrations are unavoidable in machining, but their
intensity levels can be controlled by suitable damping mech-
anisms, either active or passive. The active mechanism
Int J Adv Manuf Technol (2014) 75:12191231
provides continuously adjustable dynamic parameters based
on feedback signals from the machining process. Even though
active methods are more effective than passive methods,
complexity in design and high external power consumption
make it very expensive. Inasaki et al. [12] reported in their
paper the details of an active method applied to plunge grind-
ing by Weck and Brecher, RWTH Aachen University, Ger-
many, in the same year. In this method, a peizo-electric actu-
ator attached to the spindle-housing is activated using a feed-
back signal from the acceleration sensor and the vibrations are
suppressed. Monnin et al. [20, 21] have proposed an active
system for milling operation consisting of a peizo-electric
stack mounted at the front-end of the machine spindle. The
signal is to be obtained from an accelerometer and feedback to
the peizo-electric stack through a control circuit.
On-line methods of adjusting the damping characteristics
are easier to implement and comparatively less expensive.
Tewani et al. [35] implemented a dynamic absorber having a
force-generating piezo-electric actuator to reduce chatter in
boring operation. They demonstrated that amplitude of vibra-
tion could be reduced during the experimental trials. However,
the constructional details were not included in their paper.
Wang and Fei [40] used a specially designed sleeve for boring
bar with a provision to accomodate electro-rhelogical fluid
and damping characteristics is varied by changing the voltage
applied to the fluid. Tarng et al. [34] used a tunable vibration
absorber with piezoelectric inertia actuator for turning
operation.
Passive suppression mechanisms are simple in construc-
tion, low cost, and do not need external energy. Very early
passive damper is the one designed by F.W. Lanchester in
1910 for suppressing crankshaft vibration in automobile en-
gine. Hahn [10] has adapted Lanchesters concept of using
rubber-like material as damping-medium to suit machining
applications. Subsequently, Hahn [11] patented a boring bar
having a hollow-construction, fitted inside with a cantilever
carrying a mass at the free-end and filled with viscous fluid.
Such visco-elastic material and viscous fluid used in the
dampers are known to perform well in room temperatures,
but performance of these dampers deteriorates with tempera-
ture and time. Ema and Marui [8] developed a different design
that uses a freely moving mass inside a cavity located at the
free-end of the boring bar. Such a single-mass impact damper
with proper clearance inside the cavity of the boring bar is
effective in chatter control.
The general literature on structural vibration also deals with
both active and passive methods of damping. In an early
paper, Panossian [25] suggested a novel passive method re-
ferred to as non-obstructive particle damping for suppressing
structural vibrations. It used a small cavity appropriately po-
sitioned inside the structure and filled with particles. The
energy dissipation due to collision between the particles and
the particles with the cavity wall led to damping. Friend and
Int J Adv Manuf Technol (2014) 75:12191231 1221

A 15
10

Amplitude (gn)
05
A 0
A-A
Fig. 1 Schematic diagram of boring bar with particles filled in a cavity
-05
-10
Kinra [9] applied the particle damping method on cantilever
beam and showed 50 % improvement in damping capacity -15
0 0.5 1.0 1.5 2.0
with a very small weight penalty. Later, Marhadi and Kinra
Time (ms)
[18] extended particle impact damping (PID) method to cover
different materials and established its effectiveness. The char- a) Time Domain
acterization of particle damping has also been attempted by
Mao et al. [17], using discrete element method which simu- 200
lates the behavior of granular materials in three-dimension.

Amplitude (gn rms)

Different modeling and simulation approaches have been used 150
by Xu et al. [42] and Bai et al. [3] for prediction of the
damping effect and to have better insight and understanding 100
of PID.
Novelty of the present work is in the application of PID 50
concept in the design of special boring bar for suppression of
chatter. PID can also be considered as a derivative of single 0
mass damper used to attenuate vibration in structural ele- 0 200 400 600 800
ments. Hence, the present work provides a basis for an im- 1000
Frequency (Hz)
portant application in the manufacturing industry, particularly b) Frequency Domain
in the metal cutting industry. A specially designed boring bar
Fig. 3 Response signals from impact test: a time domain, b frequency
with PID is developed in the present work. Its damping Domain
characteristics are evaluated for different sizes and volume
fractions of spherical steel particles using impact and shaker
tests, and the results are included. Unlike structural applica- The results of surface topography investigation are presented
tions, demands are more stringent in metal cutting applica- and discussed in this paper.
tions, as improvement in the final product quality must be
demonstrated with PID boring bar. The surface topography
reveals macro- and micro-geometrical deviations present on
the surfaces [31, 41]. Therefore, the bored hole is investigated 2 Development of PID boring bar
in terms of chatter marks, surface roughness, and roundness.
2.1 Constructional details
Impact hammer
In order to implement PID, a cavity is needed in the boring
Excitaon signal bar. Though it is ideal to provide the cavity as close to insert
location, it has to be positioned away from the insert location
due to physical constraints. Further, size of the cavity must be
such that it is possible to load more particles and yet stiffness
of the boring bar must not be lowered below a specified value.
Therefore, the boring bars without cavity and with cavity at
different locations are modeled using ProE Wildfire 3 and
analyzed using ANSYS 12.0. A stiffness reduction of
12.78 % is observed in the boring bar with a cavity of
Piezoelectric Response signal 22 mm diameter located at 110 mm from insert location. This
Accelerometer is below the specified value of 15 % and hence accepted for
Fig. 2 Schematic diagram of the impact test set-up for boring bar carrying out further work.
1222 Int J Adv Manuf Technol (2014) 75:12191231

shortened to an overall length of 80 mm first. Leaving the insert

Accelerometer holding portion, end of the shortened bar is reduced to 16 mm
Boring bar
diameter for a length of 20 mm and threaded. The threaded end
of the boring bar is fastened to a longer EN24 cylindrical bar of
38 mm diameter, with an offset of 4 mm between axes to
facilitate boring operation. In order to facilitate loading of the
particles, the 38-mm-diameter cylindrical bar is split suitably
Load transfer rod and hemi-spherical cavities with 11 mm radius are machined on
both pieces. When these pieces are assembled and secured by a
threaded connection, a spherical cavity of 22 mm is formed at
the desired location of 110 mm and an overall length of boring
bar is obtained as 420 mm.
High carbon steel spherical particles of diameter 3.17, 3.96,
and 4.16 mm are considered in the present study. Volume of the
particles in the cavity of the primary structure has influence on
Load cell the performance of PID. The ratio of volume of the particles to
the volume of the cavity is referred to as volume fraction. In the
present work, three different volume fractions 30, 50, and 70 %
are selected for the three different sizes of the particles.

Exciter Plaorm 2.2 Identification of modal parameters using impact test

Fig. 4 Shaker excitation test on boring bar
Taking a cavity size of 22 mm positioned at 110 mm from
insert location, the boring bar with PID is developed as a three-
piece construction. ISO-specified WIDAX S32T PCKNR 12F3
boring bar is modified as shown in Fig. 1. The boring bar is
The dynamic behavior of the developed boring bar can be
obtained from the ANSYS. However, experimental evaluation
of dynamic behavior will include different aspects such as
joint characteristics and influence of clamping system. There-
fore, an experimental impact excitation method is adopted in
the present work to identify the natural frequency of the

100 -40
-45
Amplitude (m)

50
Force (N)

-50
0 -55
-60
-50
-65
-100 -70
20 21 22 23 24 25 26 20 21 22 23 24 25 26

Time (ms) Time (ms)

i) Time domain i) Time domain

100
10
80
Force (N)

08
Amplitude (m)

60
06
40 04
20 02

0 0
300 400 500 600 700 800 300 400 500 600 700 800
Frequency (Hz) Frequency (Hz)
ii) Frequency domain
ii) Frequency domain
b) Response signal
a) Excitation Signal

Fig. 5 Signals measured during shaker test (excitation frequency, 660 Hz; particle size, 3.17 mm, and volume fraction, 30 %). a Excitation signal (i) time
domain, (ii) frequency domain; b response signal (i) time domain, (ii) frequency domain
Int J Adv Manuf Technol (2014) 75:12191231 1223

developed boring bar. Knowing this frequency, further evalu- lbf). It has an integral force sensor which is used to determine
ation is possible with particle loading. the force exerted on the structure being excited. The intensity
The impact test is carried out with an impulse hammer of the excitation depends on the mass of the hammer and its
(DYTRAN-5800B4) of sensitivity 2.316 mv/N (10.30 mV/ velocity. An accelerometer (DYTRAN-3145AG) of

Table 1 Results from shaker excitation tests

Sl. no. Particle size, mm Volume fraction % Excitation Displacement (m) Displacement to force
ratio 105(m/N)
Frequency (Hz) Force (N)

1 3.17 30 660 79.84 6.30 7.89

2 3.17 50 103.46 3.78 3.65
3 3.17 70 142.95 6.97 4.87
4 3.97 30 93.10 46.73 50.20
5 3.97 50 34.80 4.52 13.00
6 3.97 70 134.76 6.17 4.58
7 4.76 30 49.79 2.98 5.98
8 4.76 50 68.66 3.97 5.78
9 4.76 70 78.18 5.61 7.18
10 Empty 76.92 4.76 6.19
11 3.17 30 680 28.01 2.86 10.20
12 3.17 50 111.35 4.76 4.27
13 3.17 70 132.38 6.34 4.79
14 3.97 30 86.34 25.56 29.60
15 3.97 50 39.31 4.79 12.20
16 3.97 70 141.38 6.54 4.63
17 4.76 30 74.50 4.43 5.95
18 4.76 50 72.13 4.31 5.98
19 4.76 70 71.23 5.21 7.32
20 Empty 78.73 5.02 6.38
21 3.17 30 703 28.00 2.86 10.20
22 3.17 50 169.07 6.63 3.92
23 3.17 70 84.76 3.93 4.64
24 3.97 30 51.91 3.58 6.89
25 3.97 50 9.43 2.49 26.4
26 3.97 70 98.75 4.05 4.10
27 4.76 30 50.96 3.03 5.95
28 4.76 50 44.40 2.59 5.84
29 4.76 70 38.90 3.21 8.26
30 Empty 43.06 2.76 6.40
31 3.17 30 720 14.58 2.15 14.70
32 3.17 50 127.28 4.75 3.73
33 3.17 70 56.70 2.64 4.66
34 3.97 30 31.08 2.37 7.63
35 3.97 50 4.01 1.57 39.20
36 3.97 70 73.45 2.77 3.78
37 4.76 30 34.25 2.11 6.15
38 4.76 50 31.57 1.86 5.90
39 4.76 70 20.46 2.09 10.20
40 Empty 28.63 1.94 6.76
1224
Fig. 6 Photograph of setup for
boring experiments
Workpiece
sensitivity 104.3 mV/g is used to capture the response signals.
High-quality wax is used to mount the accelerometer tempo-
rarily on the boring bar. The resonant frequencies of the
impact hammer and accelerometer are 75 and 45 kHz, respec-
tively, which are much higher than the natural frequency of the
boring bar. This condition eliminates the possibility the oc-
currence of resonance during the measurement. The charge
produced by piezoelectric crystals in both impact hammer and
accelerometers are conditioned with inbuilt amplification cir-
cuits and filters. Since insufficient excitation energy and mul-
tiple impact cause poor signal-to-noise ratio, special care has
to be taken during the excitation process. The schematic
diagram of the experimental set up is shown in Fig. 2.
For the excitation given in the depth of cut direction and the
response measured along the line of action of the impact,
response signals obtained is shown in Fig. 3a. The
Fig. 7 Effect of different particle
sizes and filling volumes on
surface roughness (speed,
n=420 rpm)
Surface Roughness Ra (m)
Int J Adv Manuf Technol (2014) 75:12191231
Accelerometer
accelerometer signals are captured at a sampling frequency
of 24 kHz. From the frequency plot of the signal shown in
Fig. 3b, natural frequency of the developed bar is obtained as
680 Hz.
2.3 Selection of particle size and volume fraction using shaker
test
In order to get the desired performance from the PID boring
bar, particle size and volume fraction must be determined. The
particle size and volume fraction are identified using the
results obtained from electro-dynamic shaker. A photograph
of the electro dynamic shaker test setup is shown in Fig. 4. The
boring bar is mounted on a specially designed fixture. In
addition to the natural frequency of 680 Hz identified by the
impact test, three more levels of discrete frequencies 660, 703,
Int J Adv Manuf Technol (2014) 75:12191231 1225

condition. The time domain signals from the load cell attached
5 to the exciter and accelerometer mounted on the boring bar are
4 shown in Fig. 5a(i) and b(i), respectively, for excitation and
Amplitude gn(rms)

3
response signals. The frequencies of both the signals are found
to be same in Fig. 5a(ii) and b(ii).
2
Results of the shaker excitation test are shown in Table 1. It
1 has been difficult to maintain the magnitude of the excitation
0
force during the shaker test experiments, as adjustment of nut
0 100 200 300 400 500 600 at the end of load transfer rod influences the loading condition.
Hz In order to compare the results, a ratio of the amplitude of
a) Without PID displacement measured to the amplitude of excitation force is
taken as a performance measure. The performance of the PID
is found to be good for 3.17-mm particle size and 50 %
5 volume fraction (shown in italics), as the displacements are
4 considerably reduced.
Amplitude gn(rms)

1
3 Boring experiments
0
0 100 200 300 400 500 600
3.1 Details of machining trials
Hz
b) With PID
For carrying out the boring operations, VDF S500 lathe,
Fig. 8 Tool vibration in radial direction (frequency domain) (feed, Germany, shown in Fig. 6 is chosen. The distance between
0.18 mm/rev; depth of cut, 0.45 mm; speed, 420 rpm). a Without PID,
b with PID the centers is 1,000 mm. Spindle speed can be varied in
discrete steps using a gear box and continuously between the
discrete speeds using a positive variable drive (PIV). Using
and 720 Hz are selected for the shaker excitation test. The such a combination of drives, spindle speed there can be
boring bar with cavity having different particle sizes and varied from 180 to 5,600 rpm. The spindle is driven by a
volume fraction is allowed to vibrate for sufficient time. When heavy duty motor of 15 kW. Such a high-power motor ensures
the system stabilizes, its response is captured with a piezo- that the spindle speed is not reduced during machining trials.
electric accelerometer of sensitivity 103.4 mV/g mounted on The spindle speed is always checked by a tachometer during
the boring bar. The output from the electro dynamic shaker actual machining, and, if there is any reduction in speed, it is
and the accelerometer are shown in Fig. 5 for a typical adjusted using PIV.

Fig. 9 Imprints of scatter marks

obtained on bored surface (feed, Clamped end Clamped end
s=0.18 mm/rev; depth of cut,
a=0.45 mm; speed, n=420 rpm).
a Without PID, b with PID

10 mm 10 mm

a)Without PID b) With PID

1226 Int J Adv Manuf Technol (2014) 75:12191231

Table 2 Acceleration measured during boring trials and presence of chatter marks

Sl. No. Cutting conditions Acceleration, g Chatter marks (angle, deg)

Feed, mm/rev Depth of cut, mm Without PID With PID Without PID With PID

1 0.18 0.45 3.48 1.94 S (19) W (9)

2 0.18 0.50 3.72 2.62 S (12) W (10)
3 0.18 0.55 1.83 2.31 S (10) W (10)
4 0.20 0.45 2.62 3.14 S (12) W (10)
5 0.20 0.50 2.38 2.94 S (14) W (12)
6 0.20 0.55 1.20 2.86 S (13) S (22)
7 0.22 0.45 4.15 1.39 S (18) W (11)
8 0.22 0.50 2.53 2.51 S (24) M (14)
9 0.22 0.55 4.00 1.17 S (20) W (10)

S strong, M moderate, W weak

For all machining trials, standard 80 diagonal inserts of
KC9320 from Kennametal are used. The projection length of
the boring bar from the support is always maintained as
170 mm. It is mounted on the tool post using three M8 screws
with uniform torque of 55 Nm. For carrying out the experi-
ments, 55-mm-long workpieces are prepared from a seamless
steel tube having inner and outer diameters of 80 and 92 mm,
respectively, and a hardness of 171 BHN. A three jaw-chuck is
used to hold the workpiece and it is tightened using a torque
wrench for a constant torque of 70 Nm. After two passes
involving rough and finishing cuts, final boring is performed
for an axial length of 50 mm. For conducting the trials, three
levels of feed, s=0.18, 0.20, and 0.22 mm/rev and three levels
of depth of cut, a=0.45, 0.50, and 0.55 mm are selected. The
machining trials for the present work are carried out at con-
stant spindle speed of n=420 rpm (105.6 m/min).
Though the particle size (3.17 mm) and volume fraction
(50 %) are determined from the shaker excitation tests, boring
trials are carried out for different particle size (4.76 mm) and
volume fractions (30, 70 %) to study the performance of the
PID boring bar in actual boring operation. The results shown
in Fig. 7 confirm that the surface roughness (details of rough-
ness measurement are given later in Section 3.2) obtained with
PID having particle size of 3.17 mm and volume fraction of
50 % is the lowest. Hence subsequent studies are carried out
with PID using 3.17-mm particle size and 50 % volume
fraction and the corresponding details are presented in the
following sections.

Fig. 10 Effect of PID on surface

roughness of bore for different
cutting conditions (speed,
n=420 rpm). White bar, without
PID; gray bar, with PID
Surface Roughness Ra (m)

s=0.18 s=0.18 s=0.18 s=0.20 s=0.20 s=0.20 s=0.22 s=0.22 s=0.22

a=0.45 a=0.50 a=0.55 a=0.45 a=0.50 a=0.55 a=0.45 a=0.50 a=0.55
Machining condions
Without PID With PID
Int J Adv Manuf Technol (2014) 75:12191231 1227

Fig. 11 Influence of PID on m

roughness profile (feed, 10.00
s=0.20 mm / rev; depth of cut,
a=1.45 mm; speed, n=420 rpm).
a Without PID (Ra =3.12 m), b -10.00
4.00 mm
0.80 mm / div
with PID (Ra =2.29 m)
a) Without PID (Ra=3.12 m)
m
10.00

-10.00
0.80 mm / div 4.00 mm
b) With PID (Ra=2.29 m)

3.2 Vibration measurement
Vibration signal during the machining process is captured in
the radial direction with a piezoelectric accelerometer of sen-
sitivity 103.4 mV/g. The sensor is mounted on the boring bar
opposite to the cutting tip and at the same location as the
cavity (110 mm from the free-end), as shown in the Fig. 6.
Results of frequency analysis for a typical machining condi-
tion are shown in Fig. 8 with and without PID.
3.3 Assessment of bore quality
The machined bores are inspected visually for the presence of
chatter marks. Preliminary attempt is made to classify the
chatter marks on the basis of their presence as strong, moderate,
and weak. Since the chatter marks are having a pattern different
from the feed marks in different orientation, attempt is also
made to take an imprint of chatter marks after lightly smearing
the bore surface with black ink and pressing a white paper
against it. Figure 9 shows imprints of chatter marks obtained
for a typical machining condition with and without PID.
In order to quantify the variations in surface topography,
surface finish measurements are done using a tracing stylus
instrument having a stylus tip radius of 2 m (MarSurf
XR20). The instrument uses a traverse velocity of 0.5 mm/s
for the stylus. A cut-off length of 0.8 mm is selected and
11,200 points are captured over a traverse length of 5.6 mm.
For each bore, surface roughness parameters such Ra, Rq, Rt,
and Rmax are measured at distance 30 mm along the axis from
the start end. In the present work, only Ra is taken for further
investigation.
Roundness error present in the machined bore is also indic-
ative of the bore quality. For measurement of roundness error,
Mahr MMQ200 roundness tester is used. The spindle is provid-
ed with a high-precision bearing arrangement. A stylus carrying
a ball of 3 mm diameter is used to capture radial variations on
the machined bore surface at a sampling angle of 0.11. A
constant contact force of 0.20 N is set between the probe and
the workpiece. All the measurements are done at a distance of
30 mm from the start end. The software used in the roundness
assessment also provides FFT analysis of the roundness profile.
4 Results and discussion
The boring trials carried out initially with an overhang of
150 mm and a tightening torque of 55 Nm on the tool did

Fig. 12 Comparison of 900 900

roundness profiles (feed,
s=0.18 mm/rev; depth of cut,
a=0.45 mm; speed, n=420 rpm).
a Without PID, roundness
error,76.21 m; b with PID,
roundness error, 48.701 m
O0 O0

15.00m 15.00m

a) without PID, Roundness error:76.21m b) with PID, Roundness error:48.701m

1228 Int J Adv Manuf Technol (2014) 75:12191231

not show any chatter marks. Unless conditions promoting 36

chatter are used, it is not possible to bring out the effectiveness
of PID in boring operation. In the present work, an overhang 32
of 170 mm and a tightening torque of 70 Nm are found to
result in chattering without PID. The chatter marks are seen to 28
have orientation different from the feed marks. Figure 7 pre-
24
sents the surface roughness obtained in boring operation with

Amplitude, m
PID having different particle sizes and volume fractions. 20
When the cavity is filled 50 % with 3.17-mm particles, the
surface quality of the bore is found to improve. This condition 16
has also been identified from the results of the shaker test
given in Table 1. Therefore, boring bar with 50 % volume 12
fraction and 3.17-mm particles is chosen for extensive inves-
tigations. Figure 8 shows the results of frequency analysis 08
obtained for boring operations with and without PID for a
typical machining condition. Comparison of the amplitudes in 04
the frequency spectrum reveals that a reduction from 3.48 to
0
1.94 is achieved with PID, confirming its effectiveness.
0 10 20 30 40 50 60 70 80 90 100
Table 2 lists the amplitudes obtained for all the machining
Harmonic
conditions with and without PID. For 0.20 mm depth of cut
and 0.55 mm feed, the amplitude has increased from 1.20 to a) without PID, 3rd harmonic amplitude =34.34m.
2.86 showing that the PID is not effective in this condition.
In Table 2, observations regarding the chatter marks are
also included using symbols, namely S for strong, M for 36
moderate, and W for weak. It is seen that PID is able to reduce
the chatter in most of the cases from strong to weak. Only for 32
0.2 mm feed and 0.55 mm depth of cut, there is no improve-
28
ment as revealed by visual examination. It may be noted from
the Table 2 that for the same condition, PID is not resulting in 24
Amplitude, m

an amplitude reduction in the frequency domain for the signals

obtained from the accelerometer placed on the boring bar. 20
Orientation of chatter marks as seen in Fig. 9 also changes
for different machining conditions with and without PID. 16
These angles are also measured and included in Table 2. A
general trend is that the chatter angle is lower with PID. Again 12
for 0.2 mm feed and 0.55 mm depth of cut, the trend is
reversed and it is a case in which there is no improvement. 08
The tool moves in the axial direction, resulting in feed
04
marks with alternate peaks and valleys and leaving a lay
pattern in the bored workpiece. The measurement of the 0
surface roughness is also done perpendicular to the feed marks
0 10 20 30 40 50 60 70 80 90 100
by the movement of the stylus in the axial direction. The
Harmonic
surface roughness values measured are shown in Fig. 10 for
different machining conditions. The roughness values b) with PID, 3rd Harmonic amplitude=21.05m
obtained in boring operation show a reduction with PID Fig. 13 Comparison of amplitudes- frequency domain (feed,
for all conditions. The surface roughness profile of the s=0.18 mm/rev; depth of cut, a=0.45 mm; speed, n=420 rpm). a Without
PID, third harmonic amplitude=34.34 m; b with PID, third harmonic
bored workpice without PID is shown in Fig. 11a. Due amplitude=21.05 m
to self-excited vibration in the machining process, low-
frequency and high-amplitude components get superimposed
with high-frequency micro-level irregularities of the surface.
The dashed arcs clearly show the low-frequency components.
With PID, energy associated with the low-frequency and high- to relative velocities of the colliding particles inside the cavity
amplitude vibration of the primary structure is dissipated due of boring bar. As a result, surface roughness values measured,
Int J Adv Manuf Technol (2014) 75:12191231 1229

Fig. 14 Effect of PID on

roundness error of bore for
different cutting conditions
(speed, n=420 rpm)

s=0.18 s=0.18 s=0.18 s=0.20 s=0.20 s=0.20 s=0.22 s=0.22 s=0.22

a=0.45 a=0.50 a=0.55 a=0.45 a=0.50 a=0.55 a=0.45 a=0.50 a=0.55
Machining condions

namely Ra, are lower with PID (Fig. 11b). Except conditions
giving 1.41 and 3.9 % improvement, improvement in surface
finish for all other conditions is varying from 25.96 to 59.5 %,
taking Ra value obtained with PID as reference value.
The self-excited vibration of cutting tool in the depth of cut
direction directly introduces radial deviations in the transverse
section of the bore being machined. In the roundness mea-
surement, stylus also measures radial deviation in the trans-
verse section. The experimentally measured roundness pro-
files show that clamping condition still influences the round-
ness profile (Fig. 12). The changing stiffness around the
workpiece due to the three-jaw chuck used to clamp the
workpiece is responsible for the three-lobed nature of the
profile. Though the three-lobes in the roundness profile cannot
be completely eliminated, an attempt is made for comparison
purposes to control its magnitude by maintaining the tighten-
ing torque at the same level (55 Nm). Damir [7] and Chien [5]
have suggested methods to arrive at the harmonic contents of
the roundness profile. Figure 13 shows the amplitudes of
different harmonics present in the roundness profiles plotted
in Fig. 12. It is seen that the PID boring bar has been effective
in reducing the roundness error in this case. For all other
conditions also, Fig. 14 shows the reduction in the roundness
error with PID. Numerically, the improvement ranges from
12.08 to 61.76 % taking roundness error obtained with PID as
reference value.
Table 3 gives the amplitudes of first prominent harmonics,
namely the third harmonics and second prominent peak.
Higher amplitudes for third harmonics are due to the critical
influence of clamping using three-jaw chuck and same phe-
nomenon has been observed by Rahman et al. [28]. Interest-
ingly, both third harmonics and second prominent harmonics
show considerable reduction in amplitude with PID. In case of
0.55 mm depth of cut and 0.18 mm feed, the second

Table 3 Amplitudes (in micrometer) of prominent harmonics in roundness profiles

Sl. no. Cutting conditions First prominent (third harmonics) Second prominent

Feed, mm/rev Depth of cut, mm Without PID With PID Without PID With PID

Number Amplitude Number Amplitude

1 0.18 0.45 34.2 20.0 82 9.4 70 2.6

2 0.18 0.50 30.5 23.5 68 7.4 70 2.2
3 0.18 0.55 27.3 21.7 70 2.8 69 5.8
4 0.20 0.45 27.6 17.6 67 3.8 70 1.8
5 0.20 0.50 28.8 20.5 66 9.8 69 7.6
6 0.20 0.55 31.2 17.1 68 9.2 79 5.5
7 0.22 0.45 29.2 18.9 74 10.8 70 2.4
8 0.22 0.50 29.7 21.8 79 8.6 70 4.6
9 0.22 0.55 29.6 20.1 81 5.6 71 1.8
1230
prominent harmonics has higher amplitude with PID. It can be
seen that first harmonics plays a major role is deciding the
effectiveness of PID in boring operation. In general, the am-
plitudes of third harmonics are reduced from 27.334.2 to
17.123.5 m. In case of higher harmonics in the range of
6682, the resulting harmonics vary from 6971 and their
amplitudes are reduced from 3.810.8 to 1.87.6 m. Con- References
sidering only the third harmonics, reduction in the amplitude
is seen to vary from 25.81 to 71 %, taking the amplitude
obtained with PID as reference value.
5 Conclusions
Using a newly designed and developed boring bar, effect of
particle impact damping in boring operation has been studied.
The experiments with PID boring bar show improvement in
roundness and surface finish of the bored workpiece. The
following conclusions can be drawn from the investigations
carried out:
1. The size and volume fraction of the particles filled in the
cavity of the boring bar is found to influence the charac-
teristics of the boring bar. A combination of particle size
of 3.17 mm and 50 % volume fraction is found to reduce
the amplitude response of boring bar as revealed by
shaker tests. The improved performance using this com-
bination is also confirmed by surface roughness obtained
during the boring trials with different particle sizes and
volume fractions.
2. PID is found to be effective in attenuating the self-excited
vibration of the boring bar. This happens due to transfer of
momentum from the primary system to the particles and
the energy dissipation caused by collision between the
particles and cavity walls in the three dimensional space,
thereby improving the stability of the boring process.
3. Since the energy dissipation in PID is a function of the
velocity of the colliding particles, low-frequency high-
amplitude vibrations are damped considerably in the ac-
tual boring process.
4. The low-frequency high-amplitude components in the
surface profile are found to be reduced using PID and
correspondingly the surface finish of the machined com-
ponent is found to improve. The improvement is as low as
1.41 and 3.9 % in two cases, but it is varying from 25.96
to 59.5 % for all other conditions.
5. The roundness error of the machined component is found
to be influenced by the clamping conditions and boring
bar vibrations. The application of PID reduces the round-
ness error and significantly limits third harmonics of the
roundness profile. The improvement in roundness varies
from 12.08 to 61.76 %, while the reduction in the ampli-
tudes of third harmonics varies from 25.81 to 71 %.
Int J Adv Manuf Technol (2014) 75:12191231
Acknowledgements We sincerely thank Mr. R.V. Gopalan, Director,
and Mr. Yogesh Gopalan, Design and Testing Engineer, at TAG Corpo-
ration, Chennai, India, for providing high-precision electro-dynamic
shaker for the study of PID characteristics of the boring bar.
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