TECHNICAL UNIVERSITY OF KENYA (TUK)

CAT II EMMU 7241: Machine Tool Vibrations and Cutting Dynamics Marking Scheme
Attempt all questions
Q1. a) A turning operation is to be performed with HSS tooling on mild steel, with Taylor tool life
parameters of n = 0.125 and C =70 m/min. If the work piece length =500mm, diameter = 100 mm,
feed = 0.25 mm/rev, handling time per piece = 5.0 min, tool change time = 2.0 min, cost of
machine and operator = KES 3,000/hr and tooling cost = KES 300 per cutting edge, determine
the: i) cutting speed for maximum production rate, ii) cutting speed for minimum cost, and iii)
Hourly production rate and cost per piece for the two cutting speeds computed in (i) and (ii) above.

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b) Consider the translational vibrations of a small rigid lathe along the cutting direction. A
model of this system has a stiffness element k= 20 x 106 N/m, an inertia element m =22.5 kg, and a
damping coefficient c = 21205N.s/m. Determine the free response of this system for a 5 mm initial
displacement and zero initial velocity. How does the nature of the response of the system change
when the damping coefficient is increased to 43,000N.s/m?

Q2. (a) What are the types of chips formed during machining various materials on the lathe?
a) Types of Chips Formed
Every machining operation involves the formation of chips. The nature of the chips depends on:
a) Operation
b) properties of the workpiece material
c) cutting environment

The chip is formed by deformation of the metal lying ahead of the cutting edge by a process of
shear. The cutting tool has to overcome the resistance of the work material to give it a desired
shape. So cutting tool must be harder, wear resistance than the w/p. The main reason for the chip
formation is due to the deformation by shear stress. This stress is applied to metal lying ahead of
the cutting edge of the tool. Four main types of chips in machining process are:
a) Continuous or Ribbon Type Chips
2 b) Continuous Chip Built-up-Edge (BUE)
c) Serrated Chips
d) Discontinuous Chips
 a) Continuous or Ribbon Type Chips
In this type of chip formation the chips are bonded together and form long coils. These are
continuous chips which undergo continuous plastic deformation. There isnt any fracture ahead of
the cutting edge of the tool. The inside part of the chip shows steps due to intermittent slip. The
outside is smooth.

This type of chip is produced while machining a ductile material, like mild steel, under favourable
cutting condition such as high cutting speed and minimum friction between the chip and the tool
face. Otherwise, it will break and form the segmental chip. The friction at the chip-tool interface
can be minimized by polishing the tool face and adequate use of coolant. Also, with diamond tool
the friction is less. The basis of the production of a continuous chip is the continuous plastic
deformation of the metal ahead of the tool, the chip moving smoothly up the tool face. Sometimes,
continuous chips are produced at low cutting speed if effective cutting fluid is used because this
type of chip is associated with low friction between the chip and the tool. Since finish is best,
power consumption is low and tool life high with this type of chip, this is most preferred type.
Other factors responsible for promoting its production are bigger Rake angle, finer Feed and Keen
cutting edge of the tool.

b) Continuous Chip Built-up-Edge (BUE)

This type of chip is very similar to that of continuous type, with the difference that it is not as
smooth as the previous one. This type of chip is obtained by machining ductile material, when high
friction exists at the chip tool interface. The upward flowing chip exerts pressure on the tool face.
The normal reaction Nr of the chip on the tool face is quite high, and is a maximum at the cutting
edge or nose of the tool. This gives rise to an excessively high temperature and the compressed
metal adjacent to the tool nose gets welded to it. The chip is also sufficiently hot and gets oxidized
as it comes off the tool and turns blue in colour. The extra metal welded to the nose or point of the
tool is called Built up Edge. This metal is highly strain hardened and brittle. With the result, as the
chip flows up the tool, the Built-up edge is broken and carried away with the chip while the rest of
it adheres to the surface of the workpiece, making it rough. Due to the Built-up-Edge the rake angle
is also altered and so is the cutting force. The common factors responsible for promoting the
formation of Build-up Edge are low cutting speed, excessive feed, small rake angle and lack of
lubricant.

Adverse effects of built up edge formation are:

a) Rough surface finish on the work piece.
b) Fluctuating cutting force, causing the vibration in cutting tool.
c) Chances of carrying away some material from the tool by the builtup surface, producing
3 crater on the tool face and causing tool wear.

To avoid the formation of built up edge the following precaution are required:
 i) The coefficient of friction at the chip tool interface should be minimized by means of
polishing the tool face and adequate supply of coolant the operation.
ii) The rake angle should be kept large.
iii) High cutting speeds and low feeds should be employed because at high speed the strain of
the weld becomes low. Similarly at very high temperature also the strain of the weld
becomes low.

c) Serrated Chips
These are semi-continuous chips, which possess a saw tooth profile; they are produced when
machining tool steels or Harden materials at high cutting speeds. The main reason for this
appearance is the alternating high shear strain followed by a low shear strain. These chips are seen
with metals like titanium alloys, austenitic stainless steel and nickel based super alloys which are
very difficult to machine. When materials are cut at very high speed these chips are likely to be
formed.
Reasons:
Ductile materials
Low-to-medium cutting speeds
Tool-chip friction causes portions of chip to adhere to rake face
BUE forms, then breaks off, cyclically

d) Discontinuous or segmental chip

These types of chips are produced during machining of hard and brittle metals like bronze, brass
and cast-iron. Sometimes, cutting of ductile metals at very low feeds with small rake angle of the
cutting tool and high speeds and high friction forces at the chip tool interface also result in the
production of discontinuous chips. Discontinuous chips in ductile materials are formed when the
hydrostatic pressure near the cutting edge is tensile or the shear energy reaches a critical value. The
formation of this type of chip in brittle materials imparts good finish, increases tool life and
consumes less power. Presence of discontinuous chips in ductile-materials results in poor-finish and
excessive tool-wear. Smaller chips are easier to dispose of.

If discontinuous chips are produced from the brittle materials, then surface finish is fair, power
consumption is low and tool life is reasonable. However when these are produced with ductile
materials, then finish is poor and tool wear is excessive. Other factors responsible for promoting the
production of Discontinuous Chips are smaller rake angle on the tool and too much depth of cut.

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(b) A lathe toolbit with a rake angle of 20 is cutting a section of an aluminum pipe with an inner
diameter of 150mm and an outer diameter of 156mm. The cut has a depth of 0.25mm and the chip
has a thickness of 0.50mm. If the lathe is turning at 200 rpm, and the measured cutting forces are
Fc = 1360N, and Ft = 568N, state the assumptions made and then determine: i) the following
values: Fs, Fn, F, N, , , , Vc, Vf, Vs; and ii) the minimum power required for the machine

Q3. a) Describe the adverse effects of vibrations and chatter in machining.

The adverse effects of chatter are summarized as follows:
i) Poor surface finish.
ii) Loss of dimensional accuracy of the workpiece.
iii) Premature tool wear, chipping, and failure, a critical consideration with brittle tool materials,
such as ceramics, some carbides, and diamond.
iv) Possible damage to the machine-tool components from excessive vibration and chatter.
v) Objectionable noise, particularly if it is of high frequency, such as the squeal heard when
turning brass on a lathe with a less rigid setup.

5(b) We have set up a lathe and are doing an orthogonal cut. The feed rate of the lathe is 0.1mm,
and the chip thickness after the cut is 0.2mm. The depth of the chip being cut is 5mm. The surface
cutting speed of the tool is 2m/s. The tool has a rake angle of 10deg. The tangential force is
measured as 200N, and the cutting force is 500N. Calculate the: i) Shear force and velocity; ii)
total energy produced in the cut, iii) energy used to shear, iv) Explain the difference between the
total and the shear energy.

Q4 (a). What are the causes and effects of vibrations? Use a graph to discuss the difficult
encountered when using dampers to isolate vibrations.

a) Causes and effects of vibrations in machines

i) Causes of vibrations in machines: The basic cause of vibration is an unbalanced force, or
system of forces (e.g. spring force acting on the weight in the case of spring and mass
system) acting on or through an elastic or resilient material (e.g. in a mass and spring
system; the unbalanced force is the spring force and the elastic material is the spring). The
unbalanced force may be due to mass unbalance, such as in an eccentrically mounted rotor,
or it may be due to the variable inertia forces in machinery, which does not move
uniformly, e.g. crank-and-connecting-rod motion, linkages, cam-follower systems. Force
unbalance can arise also from electric, hydraulic and acoustic sources, e.g. transformer
hum, water hammer, a loudspeaker, etc.
ii) Effects of Vibrations in machines: The main effects of machine vibrations are:
High stresses and force levels may be set up as a result of vibrations and in extreme
cases may lead to part failure. Such failure can be sudden or gradual, as in fatigue.
More frequently, there is increased wear of parts and unsatisfactory equipment
performance. This requires increased maintenance and may also involve downtime
of equipment. For example, in a machine tool with excessive vibrations, parts may
be inaccurately machined and subsequently rejected. In other cases, an inadequately
cushioned machine may walk away on (move) its foundation.
High vibration levels can result in objectionable noise levels. A common source of
objectionable noise in buildings is the vibration of machines that are mounted on
floors or walls.
Buildings are more likely to be damaged by strong dynamic loads such as those
generated by earthquakes. Subsequent vibration from other sources can then cause
existing cracks to develop and the structural stiffness to vary and eventually a
resonance may occur. This condition can cause the vibration to increase beyond
6 structurally safe limits.
And finally, noise may become excessive, independent of stress levels, consumer
product acceptance maybe jeopardized, and working conditions may become
unacceptable. Usually, the effects are a combination of these circumstances.
The difficult encountered when using dampers to isolate vibrations: The difficult can be
explained by using the graph below that shows the variation of transmissibility ratio (TR) against
the ratio /n for different values of damping factors, c/co.
From this graph shown below the following can be observed:
n 2
i) When , the all the curves pass through the point TR = 1 for all values of damping
factor c/co
2
ii) When /n < , then TR > 1 for all values of damping factor c/co. This means that the
force transmitted to the foundation through elastic support is greater than the force applied.
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iii) When /n > , then TR < 1 for all values of damping factor c/co.This shows that the
force transmitted through elastic support is less than the applied force. Thus vibration
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isolation is possible only in the region of /n > .
2
iv) It can also be observed from the graph that the damping is detrimental beyond /n > ,
2
and advantageous only in the region /n < . It is thus concluded that for the vibration
isolation, dampers need not to be provided but in order to limit resonance amplitude, stops
may be provided.
Graph showing the variation of transmissibility ratio

b) What do you understand by vibration isolation? Explain how it is accomplished.

7Vibration isolation is the means to mitigate unwanted oscillating disturbances or forces. This can
be a result in reducing forces or vibrations emanating from a foundation to a piece of equipment or
it can be a result of reducing forces or vibrations emanating from the equipment to its foundation.
Thus Isolation is the amount of vibrational energy that is being prevented from entering the system,
usually represented in decibels or as a percent (i.e., % Isolation = 1 - % Transmissibility). In order
to prevent these vibrations or to minimize the transmission of forces to the foundation, the
machines are mounted on springs and dampers or on some vibration isolating material.

A vibration problem can be described by source path receiver model which is also used to
characterize the noise control problem. The best solution to a vibration problem is to avoid it in the
first place. The intelligent solution to any vibration problem involves the following steps:
Characterize the system parameters (mass, stiffness, damping) by experimental methods,
manufacturers data, or a combination of both.
Model the system dynamics using a simple lumped parameter model
identify natural frequencies, look for coincidence with excitation frequencies
if excitation forces and frequencies are known, system response can be calculated
Use the model to assess the effect of changes in system parameters

c) A shaft of 100 mm diameter and 1 metre long has one of its end fixed and the other end carries a
disc of mass 500 kg at a radius of gyration of 450 mm. The modulus of rigidity for the shaft
material is 80 GN/m2. Determine the frequency of torsional vibrations.

Q5. a) A 100-kg machine tool is supported on an isolator of stiffness 700 KN/m. The machine tool
causes a vertical disturbance force of 350 N at a revolution of 3000 rpm due to machine cutting
operation. The damping ratio of the isolator is = 0.2. Calculate the: i) amplitude of motion
caused by the unbalanced force, ii) transmissibility ratio, and iii) Magnitude of the force
transmitted to ground through the isolator.

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 (b) A machine tool of mass 75 Kg is mounted on springs of stiffness 1200KN/m and a damping
factor of 0.2. A piston within the machine of mass 2 Kg has a reciprocating motion with a stroke of
80mm and a speed of 3000rev/min., assuming the motion to be SHM, determine: i) The amplitude
of the motion of the machine, and its phase angle with respect to the exciting force; ii) The force
transmitted to the foundation, and its phase angle with respect to the exciting force.
b)

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Q6 (a) (i) Explain why the cutting force, Fc, increases with increasing depth of cut and decreasing
rake angle.
(ii) What are the effects of performing a cutting operation with a dull tool tip or a very sharp tip?

(i) Cutting force, Fc

Increasing the depth of cut means more material being removed per unit time. Thus, all
other parameters remaining constant, the cutting force has to increase linearly because the
1 energy requirement increases linearly.
0
 As the rake angle decreases, the shear angle decreases and hence the shear strain increases.
Therefore, the energy per unit volume of material removed increases, thus the cutting force
has to increase. Note that the rake angle also has an effect on the frictional energy.
(ii) Effect of Using of a dull tool tip
There are several effects of a dull tool. A dull tool is one having an increased tip radius. As the tip
radius increases (i.e., as the tool dulls), the cutting force increases due to the fact that the effective
rake angle is now decreased; shallow depths of cut may not be possible. Another effect is the
possibility for surface residual stresses, tearing, and cracking of the machined surface, due to severe
surface deformation and the heat generated by the dull tool tip rubbing against this surface. Dull
tools also increase the tendency for BUE formation, which leads to poor surface finish.
(b) The table below gives data obtained from experiments carried out on orthogonal cutting. In both
cases, depth of cut (feed) to = 0.13 mm, width of cut = 2.5 mm, rake angle = 50, and cutting
speed V = 2 m/s.
Work piece material
Aluminum Steel
Chip thickness, tc, mm 0.23 0.58
Cutting force, Fc, N 430 890
Thrust force, Ft, N 280 800
Work piece properties are:
Flow strength Yf , MPa 120 325
Thermal diffusivity, K, mm2/s 97 14
20
Volumetric specific heat, c, N/mm C 2.6 3.3
Determine the: i) shear angle , ii) friction coefficient , iii) shear stress , and shear strain on the
shear plane, iv) chip velocity Vc,; v) shear velocity Vs, vi) Energies uf , us and ut (and power); vii)
Estimate the temperatures for the given work piece properties.

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Q7. a) A uniform shaft 100mm diameter is held in a lathe machine chuck, A, at one end and
supported at the other end but free to rotate. The shaft carries two rotors B and C which are to be
machined. The shaft plus the chuck and the two rotors can be considered as a three-mass torsional
system. If IA= IB = 600 Kg-m2 and IC = 320 Kg-m2, sketch the system and then determine: a) The
length BC if AB = 900 mm; b) The torsional stiffness of the shaft BC to make the first natural
frequency 6 Hz; c) The corresponding second natural frequency. Assume G = 80 GN/m2

a)

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3b) A stainless-steel bar 200mm diameter, is being turned on a lathe at 600 rpm and at a depth of
cut, d = 2.54 cm. If the power of the motor is 3750 W, a mechanical efficiency is 80% and the
power requirement for the material is assumed to be 68.25 W-min/m3, what is the maximum feed
that you can have at a spindle speed of 500 rpm before the motor stalls?

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