Optimization of vibration amplitude ratio of face mill tool of VMC and analysis with design expert to endorsing shim design

Abstract

This paper presents the concept, design and development of shim (passive damper) to improve the stability for high spindle speed machine operation of face mill tool. The objective of this paper is to learning the dynamic behavior of a face mill tool on VMC with dissimilar types of shims which cover investigation of dynamic motion behavior of the face mill tool, the behavior of different types of shim design and behavior of vibration by using the amplitude ratio method and analysis by a Design Expert. Research work supported computational analysis with Ansys, 35 VMC experimental records and analyzed by ANOVA/Design Expert with different type of shims to observe a dynamic behavior of chatter. It include of the effect of process parameters like Cutting speed (250,200,150 m/min), feed per tooth (0.05, 0.1, 0.15mm/tooth), depth of cut (1.2 mm, 1.0 mm, 0.8 mm), and different types of materials (shims) for face mill tool on VMC, for analyzing the responses like amplitude ratio in X – direction, Y- direction with ANOVA and optimizing for AISI 2062 steel by Design Expert. An experimental methodology was developed using the DOE (Design of experiment) technique. The optimum factorial method was used to design an orthogonal array of four factors having three levels. Here, the main results are based on amplitude ratio, ANOVA analysis and optimization. ANOVA was used to decide the effects of the machining parameters on the vibration amplitude ratio in X; and vibration amplitude ratio in Y. This is useful for evaluating the stability of milling operations via time domain FFT and analyzed by ANOVA. Data are validated by 35 sets of VMC experiments. Physical 35 experiments may be not enough in a view of high level researchers, academicians and industrialist to conclude the use of shim and it need in face mill tool on VMC. Hence here optimization based on optimum factorial method is executed using Design Expert software in which 35experiments and its iterations with 70 populations were used to run the program. It is found that the most critical parameter in this study is the material of Shim. At high cutting parameters carbide shim, at low and medium cutting parameters SS shim are given better results by ANOVA and Optimization of Design Expert also validated by 35 sets of VMC experiments. Hence these shim designs endorse versatile solutions.