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Int J Adv Manuf Technol (2011) 53:453–461

DOI 10.1007/s00170-010-2872-3

ORIGINAL ARTICLE

Prediction of vibration amplitude from machining


parameters by response surface methodology in end milling
P. S. Sivasakthivel & V. Velmurugan & R. Sudhakaran

Received: 16 March 2010 / Accepted: 28 July 2010 / Published online: 10 August 2010
# Springer-Verlag London Limited 2010

Abstract Decreasing vibration amplitude during end mill- 1 Introduction


ing process reduces tool wear and improves surface finish.
Mathematical model has been developed to predict the Chatter vibrations are detrimental to the work piece and
acceleration amplitude of vibration in terms of machining cutting tool as it may cause premature tool failure and poor
parameters such as helix angle of cutting tool, spindle surface finish. The various members of the machine tool
speed, feed rate, and axial and radial depth of cut. Central were subjected to different loading because of change in
composite rotatable second-order response surface method- work and cutter geometry, wide range of feed and speed
ology was employed to create a mathematical model, and combinations, and varying depth of cut. This results in a
the adequacy of the model was verified using analysis of complete vibratory system with complex dynamic behavior.
variance. The experiments were conducted on aluminum Al Prediction of the vibration of the machine tool is of great
6063 by high-speed steel end mill cutter, and acceleration concern as it helps to increase quality of machining. End
amplitude was measured using FFT analyzer. The direct and milling is a prominent milling process in manufacturing,
interaction effect of the machining parameter with vibration which was employed for making profiles, slots, engraves,
amplitude were analyzed, which helped to select process contours, and pockets in various components. It is quite
parameter in order to reduce vibration, which ensures understandable that the rigidity of the machine tool and
quality of milling. cutting system has a great deal to do with chatter proneness.
A tool monitoring system is required to predict the
Keywords Response surface . FFT analyzer . vibration with respect to cutting parameters to ensure good
Analysis of variance . Vibration monitoring quality surface and reduced tool wear.
Mathematical models based on the static behavior have
been proposed by many researchers [1–7]. However, the
modern manufacturing industries, which demand high-
quality products, compelled to include the influence of
vibration to obtain a dynamic model [8]. Multi-frequency
P. S. Sivasakthivel (*) : R. Sudhakaran analysis gives acceptable results at stable cutting directions
Department of Mechanical Engineering, corresponding to very low directional factors for end
Kumaraguru College of Technology,
milling process [9], and helix angle has a very important
Coimbatore, India
e-mail: sakthi_2011@yahoo.co.in effect on the stability. Chelladurai [10] developed artificial
neural network model and empirical model based on full-
R. Sudhakaran
e-mail: absudha@yahoo.com factorial experimental design to analyze the effect of
various cutting speeds, depth of cut, feed rate, and flank
V. Velmurugan tool wear on vibration. They concluded that vibration
Principal,
propagates tool wear, and hence, it affects the quality of the
Sree Sakthi Engineering College,
Coimbatore, India component. Orhan [11] revealed that increase in the
e-mail: velgoudham_v@yahoo.com vibration amplitude results in increase in tool wear. Weinert
454 Int J Adv Manuf Technol (2011) 53:453–461

[12] focused on the presentation of a time domain There are many parameters; almost all the components of
simulation concept for predicting regenerative work piece machine tool and tool system are involved in the generation
vibration of five-axis milling process. of chatter vibration. In general, chatter vibrations occur due
Monitoring of machine condition plays a very important to lack of rigidity in the machine tool and cutting condition.
role in manufacturing high-quality and low-cost compo- Altering machine tool is not possible, but predicting the
nents. Development of such system requires reliable right cutting condition to reduce the chatter is possible by
machining data that reflect the machining process. Zhang controlling the process parameter of the end milling. In our
[13] proposed and demonstrated a tool condition monitor- study, the process parameters selected are helix angle of
ing in end milling based on the vibration signal collected cutting tool, spindle speed, feed rate, and axial and radial
through microcontroller-based data acquisition. Nakagawa depth of cut. The vibration amplitude is measured by using
[14] in his work proposed a new method of monitoring twin-channel FFT analyzer (COCO 80), and the accelera-
chatter vibration in end milling of hardened steels and tion amplitudes are picked at two locations, one in the feed
concluded that vibration frequencies differed during high direction on the work piece holder and the other in the axial
and low cutting speed conditions. Rahim [15] developed cutting direction in the spindle. The resulting vibration
vibration measuring unit using a microelectromechancial measurement in terms of displacement, velocity, and
system accelerometer, and experimental tests were carried acceleration amplitude collected in the form of time
out to characterize the device and the preliminary tests waveforms and frequency spectrum are shown in Figs. 1
proved that the developed measurement unit is capable of and 2, respectively.
sensing, measuring, and condition monitoring. Tansel [16] The time wave form is a time domain analysis which uses
estimated wear and tool breakage by using acoustic the history of the signal. The signal is stored in the analyzer,
emission signals. and any non-steady or transient impulses are noted. Discrete
Chatter vibrations can occur due to both regenerative damages due to built-up edge formation, resonance condition
and non-regenerative effects and depend upon many can be identified from the wave form. The acceleration
parameters such as the cutting speed, the feed rate, the waveform indicates that pulse occurs periodically with a
axial depth of cut, and the spindle speed [17]. During period of 2 s. The frequency spectrum is a plot of the
cutting, the measurement of vibration on spindle and tool is amplitude of the vibration response versus frequency and can
of great importance in both the development and monitor- be derived by using digital fast Fourier analysis of the
ing of high-speed milling [18]. Under a normal cutting waveform. The peak level is the indication of maximum
condition in the milling process, the dominant frequency vibration generated in the milling, and the maximum
components in the spectrum graph are around the tooth acceleration amplitude of the milling is noted for our study.
passing frequency [19]. In milling, the dominant frequency components in the
In this present work, the main objective is to develop a spectrum graph are around tooth passing frequency (ft) and
mathematical model to predict the vibration amplitude in their harmonics [20]. The tooth passing frequency (ft) can
terms of machining parameters such as helix angle of be calculated from the following equation
cutting tool, spindle speed, feed rate, and axial and radial
nX N
depth of cut. During milling, the vibration amplitude is Tooth passing frequencyðft Þ ¼ ðHzÞ ð1Þ
measured in both cutting and feed directions. The mathe- 60
matical model helps us to study the direct and interaction where N=spindle speed (rpm) and n=number of teeth of
effect of each parameter. end mill cutter.
The vibration resulted by the interaction of the tool and
work piece has characteristic frequency with the multiples of
2 Vibration analysis tooth passing frequency at 1×, 2×, 3×, etc. In Fig. 2, for the
given set of machining parameters, the dominant frequency
During milling, the cutter and work piece move with each occurs at the second multiples of tooth passing frequency,
other with a frequency determined by the natural frequency i.e., at 333.33 Hz. It is due to the fact that the second
of the machine tool. Chatter is a resonant vibration that multiples of tooth passing frequency coincide with the
occurs when forces acting on the cutting tool cause it to natural frequency of the machine tool resulted in resonance.
vibrate at a natural frequency of the machine in which a
minimum excitation produces maximum amplitude. Once
this condition is established, the interaction between the 3 Experimental design
cutter and work piece will sustain vibration, and constant
pounding will reduce tool life and impair surface finish, and In the present work, helix angle of cutting tool, spindle
also high amplitude may cause damage to machine tool. speed, feed rate, and axial and radial depth of cut have been
Int J Adv Manuf Technol (2011) 53:453–461 455

Fig. 1 Waveform obtained from


the twin-channel FFT analyzer

considered as the process parameters for cutting condition parameter variable. Box and Hunter [21] proposed central
monitoring, and the peak acceleration amplitude measured composite rotatable design for fitting a second-order
in the feed and axial cutting direction is taken as a response response surface based on the criterion of rotatability. The
variable (Table 1). selected design plan [21] chosen consists of 32 experiments
Response surface methodology is the most informative (Table 3). It is five factors—five levels central composite
method of analysis of the result of a factorial experiment. rotatable design consisting of 32 sets of coded conditions.
The response acceleration amplitude of the vibration A can The design for the above said experiment comprises of a 1/2
be expressed as a function of process parameters helix replication of 25 (=16) factorial design plus six center points
angle (α), spindle speed (N), feed rate (Z), and axial (X) and and ten star points. These correspond to first 16 rows, the
radial depth of cut (Y). last six rows, and rows from 17 to 26, respectively, in the
design plan shown.
Acceleration; A ¼ fðaiu ; Niu ; Ziu ; Xiu ; Yiu Þ þ eu ð2Þ
For 1/2 replicate, the extra point included to form a
where f=response surface, eu =residual, u=no of observa- central composite design, α becomes 2ðk1Þ=4 ¼ 2. The
tions in the factorial experiment, and iu represents level of upper limit of the parameter is coded as 2; lower limit, as
the ith factor in the uth observation. −2; and the coded values for intermediate values were
When the mathematical form of f is unknown, this calculated from the following relationship [22]:
function can be approximated satisfactorily within the
2ð2X  ðXmax þ Xmin ÞÞ
experimental region by polynomials in terms of process Xi ¼ ð3Þ
ðXmax  Xmin Þ
where,
Xi The required coded value of a variable X
X Is any value of the variable from Xmin to X max
Xmin Is the lower limit of the variable
Xmax Is the upper limit of the variable

The intermediate values are coded as −1, 0, and 1.

4 Experimental setup

The experiments were conducted on a HASS vertical


machining center: model tool room mill with high-speed
steel end mill cutter under dry condition. The work piece
Fig. 2 Spectrum obtained from the twin-channel FFT analyzer material was aluminum alloy (Al 6063) commonly avail-
456 Int J Adv Manuf Technol (2011) 53:453–461

Table 1 Parameters and levels


in milling Parameter Units Factor levels

−2 −1 0 1 2

Helix angle (α) Degree (°) 30 35 40 45 50


Spindle speed (N) rpm 2,000 2,500 3,000 3,500 4,000
Feed rate (Z) mm/rev 0.02 0.03 0.04 0.05 0.06
Axial depth of cut (X) mm 1.5 2 2.5 3 3.5
Radial depth of cut (Y) mm 1.5 2 2.5 3 3.5

able machinable metal, which finds application in automo- where b0 =constant, bi =linear term coefficient, bii =quadratic
bile and valve industries. The dimension of the work piece term coefficient, and bij =interaction term coefficient.
specimen was 32 mm×32 mm in cross section and 40 mm The values of the coefficients of the polynomials were
in length. The vibration amplitude is measured by using calculated by multiple regression method. A statistical
twin-channel FFT analyzer (COCO 80), shown in Fig. 3. software QA Six Sigma DOEPC IV was used to
The acceleration amplitude is measured in the feed calculate the values of these coefficients. The second-
direction on the work piece holder (channel I) and in the order mathematical model was developed by neglecting
axial cutting direction in the spindle (channel II). The data the insignificant coefficients of the acceleration ampli-
are acquired in the FFT analyzers and are tabulated to tude measured in the feed direction and in the axial
obtain the mathematical model (Table 3). cutting direction.
For accelerometer—channel I—Vice

5 Development of mathematical model Acceleration amplitude ðaÞ


¼ 1; 245:954  798:421a  242:455Z
The general form of a quadratic polynomial, which gives
the relation between response surface y and the process  378:894X þ 516:118a2 þ 43:479aN
variable x under investigation is given by
þ 185:439aZ þ 363:649aX  149:642aY
X X X
y ¼ b0 þ i¼1 bi xi þ
k
i¼1 bii xi þ
k 2
i<j bij xi ð4Þ þ 276:585NX þ 505:267ZX  147:857ZY ð5Þ

For accelerometer—channel II—spindle

Acceleration amplitude ðaÞ

¼ 2; 036:312  874:225a þ 238:919 N

 40:303 X þ 187:386 Y þ 440:106a2

þ 491:559 N 2 þ 371:511Z 2 þ 342:731X 2

þ 301:854Y 2 þ 87:012aN þ 33:933aX


 41:215 NZ  91:484 NX þ 39:568 ZY

 36:045 XY ð6Þ

Where
α helix angle in (°)
Z feed rate in mm/rev
Y radial depth of cut in mm
N cutting speed in rpm
X axial depth of cut in mm

The adequacy of the model was tested using the analysis


of variance technique (Table 2). The calculated F ratio of
Fig. 3 Experimental setup for vibration amplitude measurement the model does not exceed the standard value, and the
Int J Adv Manuf Technol (2011) 53:453–461 457

Table 2 Adequacy of the model

Response Factors df Lack of fit—df Pure error F ratio R ratio Whether model is adequate

Model Standard model standard

Acceleration I 11 11 9 2.849 3.10 612.73 3.10 Adequate


Acceleration II 15 10 6 3.15 4.06 603.479 3.94 Adequate

calculated R ratio of the model is above the standard value 6 Results and discussion
for a desired 95% level of confidence. It is evident from
Table 3 that the error between the experimental value and A mathematical model was developed to predict the
predicted value is less than 5%. acceleration amplitude in feed and axial cutting direction

Table 3 Experimental design—central composite design matrix

Specimen no. Control factors Acceleration amplitude—(channel 1)×103mm/s2 Acceleration amplitude—(channel 2)×103mm/s2

α N Z X Y Observed value Predicted value % Error Observed value Predicted value % Error

01 −1 −1 −1 −1 1 4.8922 4.8538 0.8 4.9468 4.8318 2.3


02 1 −1 −1 −1 −1 1.8513 1.7761 4.1 2.4877 2.4737 0.6
03 −1 1 −1 −1 −1 3.6187 3.6186 0.0 5.0586 5.0333 0.5
04 1 1 −1 −1 1 1.3430 1.3063 2.7 3.6757 3.7587 −2.3
05 −1 −1 1 −1 −1 2.6790 2.6882 −0.3 4.5434 4.4674 1.7
06 1 −1 1 −1 1 0.3792 0.3522 5.1 3.0060 3.0030 0.1
07 −1 1 1 −1 1 2.0403 2.0516 −0.6 5.4628 5.3977 1.2
08 1 1 1 −1 −1 0.5059 0.4810 4.9 3.2288 3.2294 0.0
09 −1 −1 −1 1 −1 1.2319 1.2100 1.8 4.5926 4.5707 0.5
10 1 −1 −1 1 1 0.1879 0.1783 5.1 2.9015 2.9396 −1.3
11 −1 1 −1 1 1 2.2221 2.2712 −2.2 5.0085 4.9975 0.2
12 1 1 −1 1 −1 0.8417 0.8220 2.3 3.2257 3.2674 −1.3
13 −1 −1 1 1 1 1.6051 1.6640 −3.7 5.0392 4.9558 1.7
14 1 −1 1 1 −1 1.3845 1.3741 0.8 2.6886 2.7193 −1.1
15 −1 1 1 1 −1 2.0982 2.1266 −1.4 4.6061 4.6124 −0.1
16 1 1 1 1 1 1.3950 1.4192 −1.7 3.3599 3.4876 −3.8
17 −2 0 0 0 0 4.9679 4.9073 1.2 5.3602 5.5452 −3.5
18 2 0 0 0 0 1.6283 1.7136 −5.2 2.2116 2.0483 5.4
19 0 −2 0 0 0 1.2165 1.2460 −2.4 3.4133 3.5247 −3.3
20 0 2 0 0 0 1.3111 1.2460 5.0 4.5701 4.4804 2.0
21 0 0 −2 0 0 1.6593 1.7309 −4.3 3.4165 3.5224 −3.1
22 0 0 2 0 0 0.8016 0.7610 5.1 3.6065 3.5224 2.3
23 0 0 0 −2 0 1.9078 2.0037 −5.0 3.3913 3.4878 −2.8
24 0 0 0 2 0 0.5147 0.4882 5.1 3.4015 3.3266 2.2
25 0 0 0 0 −2 1.2164 1.2460 −2.4 2.8508 2.8690 −0.6
26 0 0 0 0 2 1.3102 1.2460 4.9 3.6150 3.6185 −0.1
27 0 0 0 0 0 1.2264 1.2460 −1.6 2.0106 2.0363 −1.3
28 0 0 0 0 0 1.2346 1.2460 −0.9 2.0190 2.0363 −0.9
29 0 0 0 0 0 1.2439 1.2460 −0.2 2.0941 2.0363 2.8
30 0 0 0 0 0 1.2195 1.2460 −2.2 2.0106 2.0363 −1.3
31 0 0 0 0 0 1.2296 1.2460 −1.3 2.0213 2.0363 −0.7
32 0 0 0 0 0 1.2460 1.2460 0.0 2.0841 2.0363 2.3
458 Int J Adv Manuf Technol (2011) 53:453–461

by relating it with process parameters such as helix


angle, spindle speed, feed rate, axial depth of cut, and
radial depth of cut. The direct and the interaction effects
of these process parameters on acceleration amplitude
were calculated plotted are shown in Figs. 4, 5, 6, 7, 8, 9,
10, and 11, and the cause and effect were analyzed. The
trends of the potted direct and the interaction effect of
these process parameters help to determine which param-
eter and parameter interactions are statistically significant
in decreasing the acceleration amplitude of vibration. For
acceleration amplitude in the feed and axial cutting
direction, most of the parameters are found to be
apparently significant because the levels of significance
of each parameter and interaction parameter factors are Fig. 5 Direct effect of spindle speed in axial cutting direction
almost the same. (channel-II)

6.1 Direct effect of variables takes the full load and the cutting forces increase rapidly.
The force continues to increase until the tooth leaves the cut
In this work, the effects of helix angle, spindle speed, feed and then suddenly drops. The shock load produced acts
rate, axial depth of cut, and radial depth of cut were with the drive mechanism of the machine to produce
experimentally investigated. From Figs. 4, 5, 6, 7, and 8, it chatter. The use of helical cutter instead of a straight one
is clear that the helix angle, feed rate, and axial depth of cut eliminates chatter vibration [23]. It is evident from Fig. 3
have a significant effect on acceleration amplitude in the that the acceleration amplitude gets decreased by increasing
feed direction and in the axial cutting direction. the helical angle of the cutting tool, and it is optimal at an
angle of 45°.
6.1.1 Direct effect of helix angle
6.1.2 Direct effect of spindle speed
Figure 4 shows that the increase in helix angle resulted in
reduced vibrations in both the channels measured along From Fig. 5, it is understandable that the spindle speed has
feed and axial cutting direction, and for helix angle 45°, the a significant effect on vibration when it is picked up in the
vibration is minimal in both cases. The cutting action of axial cutting direction and not significant in the feed
the tooth formed by a straight flute is intermittent. When the direction. The cutting forces acting on the tool are sustained
tooth enters the work piece, the whole length of the tooth by the spindle speed in the axial direction, and in the feed
direction, the force is sustained by the work piece fixture. It
is evident from the experiments that the vibration picked up
in the spindle (channel II) has a significant value for spindle

Fig. 4 Direct effect of helix angle in feed direction (channel-I) and in


axial cutting direction (channel-II) Fig. 6 Direct effect of feed rate in feed direction (channel-I)
Int J Adv Manuf Technol (2011) 53:453–461 459

Fig. 7 Direct effect of axial depth of cut in feed direction (channel-I)


and in axial cutting direction (channel-II) Fig. 9 Contour graph of interaction effect of feed rate×axial depth of
cut in feed direction (channel I)

speed, whereas vibration picked up in the feed direction


(channel I) is not significant. By increasing the spindle reduces the rubbing action between tool and work piece. It
speeds, the tendency of chatter decreases, but only up to a is concluded from Fig. 5 that the acceleration amplitude
certain threshold value. After a certain limit, the tool will reduced with increase in feed rate.
tend to deflect more, which induces vibration. Observation
made in Fig. 4 supports the earlier statement that the 6.1.4 Direct effect of axial depth of cut
vibration amplitude decreases with increase in spindle
speed up to 3,000 rpm and higher value above 3,000 rpm, The axial depth of cut has a significant effect on
resulting in increased amplitude of vibration. acceleration amplitude picked up in both directions. From
Fig. 7, it is quite understandable that the increase in depth
6.1.3 Direct effect of feed rate of cut resulted in reduced vibration. Increase in depth of cut
makes the tool work piece stable, which resulted in reduced
Figure 6 indicates that the feed rate has a significant effect vibration. Asymptotic border line of stability (minimum
on vibration when it is picked up in the feed direction and borderline of stability) occurs at critical depth of cut [20].
not significant in the axial cutting direction. The tendency Asymptotic border line of stability is the line in the stability
of chatter vibration got reduced by increasing the feed rate chart for a machine tool below in which no chatter occurs.
[23]. Increase in feed rate transfers much of the cutting to It is evident from Fig. 7 that in the axial direction, the
material below the hardened layer, and the tool cutter critical axial depth of cut is found to be between 2 and
makes a few turns to complete a given surface, which 2.5 mm, above which the acceleration amplitude increases.

Fig. 8 Direct effect of radial depth of cut in axial cutting direction Fig. 10 Contour graph of interaction effect of helix angle×axial depth
(channel-II) of cut in feed direction (channel I)
460 Int J Adv Manuf Technol (2011) 53:453–461

contour graph (Fig. 9) reveals that as feed rate increases, it


results in the decrease in acceleration amplitude. The same
trend continues for the change of level of axial depth of cut
from 1.5 to 2.5 mm. The increase in feed rate with the
change of level of axial depth of cut in increasing order has
not prompted the adhering effect of the aluminum. The
trend gradually gets reversed at change of level from 2.5 to
3 mm axial depth of the cut; increase in feed rate resulted in
increased vibration. The adhering property of aluminum
work piece induces shock load, which drastically resulted
in the change of trend. The same trend happened in the
level of 3 mm, wherein axial depth of cut continues for
3.5 mm.

6.2.2 Interaction effect of helix angle and axial


Fig. 11 Contour graph of interaction effect of spindle speed×axial
depth of cut in feed direction (channel I)
depth of cut

6.1.5 Direct effect of radial depth of cut The interaction effects of helix angle and axial depth of
cut on acceleration amplitude in the feed direction
From Fig. 8, it is understandable that the radial depth of cut (Fig. 10) show that increase in helix angle resulted in
has a significant effect on vibration when it is picked up in decrease of acceleration amplitude with descending order
the axial cutting direction. By decreasing the width of cut, the for all the levels of axial depth of cut. The trends were
tendency of vibration can be reduced [20]. The tool deflection found to get slightly changed at helix angle of 45°, and
in the decreased width of cut is minimal, which will reduce for the last level, the acceleration amplitude increases
the tendency to chatter. It is concluded from Fig. 8 that the with the increase in helix angle for ascending order of all
acceleration amplitude reduced with decrease in depth of cut the levels of axial depth of cut. The increase in flute angle
and the vibration is minimal at radial depth of 2 mm. will reduce shock load and hence results in reduced
vibration.
6.2 Interaction effect of variables
6.2.3 Interaction effect of spindle speed and axial
A strong interaction was observed between various process depth of cut
parameters for vibration amplitude measured in both feed
direction and axial cutting direction. The most significant The interaction effects of spindle speed and axial depth of
interaction effect was found in the feed direction. The contour cut on acceleration amplitude in the feed direction (Fig. 11)
graph between the most significant process parameter indicate that for the first three levels of axial depth of cut,
interactions is shown in Figs. 9, 10, and 11. The following increase in spindle speed resulted in decrease of accelera-
conclusion can be made from these interaction plots. tion amplitude. The trend slightly gets reversed at the last
two levels of axial depth of the cut; increase in spindle
6.2.1 Interaction effect of feed rate and axial depth of cut speed resulted in increased vibration. The threshold for both
the parameters lies in the middle level, which gives a
The interaction effect of feed rate and axial depth of cut on minimum vibration when both parameters are considered at
acceleration amplitude in the feed direction shown in the a time.

Table 4 Results of conformity test

Specimen no. Control factors Acceleration amplitude—(channel 1)×103mm/s2 Acceleration amplitude—(channel 2)×103mm/s2

α N Z X Y Observed value Predicted value % Error Observed value Predicted value % Error

01 −2 −2 −2 −2 −2 10.1132 10.4577 −3.4 10.8893 10.7709 1.1


02 −1 −1 −1 −1 −1 4.3789 4.2588 2.7 4.3807 4.4641 −3.6
03 2 2 2 2 2 4.5893 4.7786 −4.1 9.0062 8.818 2.1
Int J Adv Manuf Technol (2011) 53:453–461 461

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