Computers ind. Engng, VoL 31, No. 3/4, pp.

637 - 644, 1996

Pergamon Copyright © 1995 China Machine Press
Published by Elsexqer Sctence Ltd. thinted in Great Britain
S0360-8352(96)00235-5 0360-8352/96 $15.00 + 0.00

EFFECT OF TOOL VIBRATIONS ON SURFACE ROUGHNESS

DURING LATHE DRY TURNING PROCESS

Thomas M., Beauchamp Y., Youssef A.Y., Masounave J.

Professor, Mechanical Engineering Department
I~cole de technologie sup~rieure
4750, ave Henri-Julien, Montr6al, Canada, H2T 2C8

ABSTRACT

Choice of optimized cutting parameters is very important to control the required surface quality. In fact,
the difference between the real and theoretical surface roughness can be attributed to the influence of
physical and dynamic phenomena such as: built-up edge, friction of cut surface against tool point and
vibrations. The focus of this study is the collection and analysis of surface roughness and tool vibration
data generated by lathe dry turning of mild carbon steel samples at different levels of speed, feed, depth
of cut, tool nose radius, tool length and work piece length. A full factorial experimental design ( 288
experiments ) that allows to consider the three-level interactions between the independant variables has
been conducted. Vibration analysis has revealed that the dynamic force, related to the chip-thickness
variation acting on the tool, is related to the amplitude of tool vibration at resonance and to the variation
of the tool's natural frequency while cutting. The analogy of the effect of cutting parameters between
tool dynamic forces and surface roughness is also investigated. The results show that second order inter-
actions between cutting speed and tool nose radius, along with third-order interaction between feed rate,
cutting speed and depth of cut are the factors with the greatest influence on surface roughness and tool
dynamic forces in this type of operation and parameter levels studied. The analysis of variance revealed
that the best surface roughness condition is achieved at a low feed rate (less than 0.35 mm/rev), a large
tool nose radius (1.59 mm) and a high cutting speed (265 m/min and above). The results also show that
the depth of cut has not a significant effect on surface roughness, except when operating within the built-
up edge range. It is shown that a correlation between surface roughness and tool dynamic force exist only
when operating in the built-up edge range. In these cases, buiit=ul~edge formation deteriorates surface
roughness and increases dynamic forces acting on the tool. The effect of built-up edge formation on
surface roughness can be minimized by increasing depth of cut and increasing tool vibration.

Key words: design of experiments, lathe dry turning operation, full factorial design, surface rough-
heSS, measurements, cutting parameters, tool vibrations.

1.0 INTRODUCTION

In machining operation, the quality of surface finish is an important requirement for many turned work
pieces. Thus, the choice of optimiT~! cutting parameters ~ very important to control the required
surface quality. A large number of analytical and experimental studies on surface roughness related to
turning operations has been conducted, as shown by a review of the literature [ 1,5,6,9,12,13]. However
in the studies just mentioned, the interactions between the cutting parameters were not taken into con-
sideration in the modeling process. In fact, surface roughness can be affectedby many other factors, such
637
638 18th International Conference on Computers and Industrial Engineering

as built-up edge formation and vibrations. The analysis of tool vibration on surface roughness was also
investigated by some authors [7.8.10, i 1.15 ]. The purpose of this paper is to investigate the effects of tool
vibration on the resulting surface roughness in the dry turning operation of carbon steel. To achieve such
objective, the authors have completed a full factorial experimental design [2,3k4, 14,16] that allowed to
consider the three-level interactions between the cutting parameters ( cutting speed, feed rate, tool nose
radius, depth of cut, tool length and work piece length) on the two measured de~ndant variables (surface
roughness and tool vibration). Tool vibration analysis [ 14] has revealed that cu~ing parameters not only
have an effect on the amplitude of vibration, but also on the variation of the tool's natural frequency. The
dynamic forces, related to the chip-thickness variation, acting on the tool has been related to the amplitude
of vibration at the tool' s natural frequency and to the variation of this resonance frequency while cutting.
An analogy of the effect of cutting parameters between surface roughness and tool dynamic forces is also
investigated.

2.0 NOMENCLATURE

S cutting speed (m/min)

f feed rate (mm/revolution)
D depth of cut (mm)
r tool nose radius (mm)
W work piece length (cm)
T tool length (nun)
R surface roughness average value (ttm)
df degree of freedom
SS sum of squares
F Fisher statistic
M equivalent mass of the tool (kg)
K equivalent stiffness of the tool (N/m)
C equivalent damping of the tool (Ns/m)
x"(t) tool acceleration (m/s0
x'(t) tool speed (m/s)
x(t) tool deflection (m)
X amplitude of tool displacement
o0 initial natural frequency of the tool (Hz)
COt natural frequency of the tool while cutting (Hz)
AK chip-thickness coefficient (N/m)
AF(O tool dynamic force (N)
P inebability of type I error

3.0 EXPERIMENTAL DESIGN AND PROCEDURE

A full factorial design was chosen, so that all interactions between the independent variables could be
effectively investigated. The independent variables in the study were: cutting speed, feed rate, depth of
cut. tool nose radius, work piece length and tool lcngth. The last two variables were introduced into the
experiment since we suspect that the vibrations generated by varying the work piece length and tool
length could affect the resulting surface finish since the natural frequencies are modified. The two
dependent variables are the resulting first cut surface finish and and the tool dynamic forces. The levels
of the independent variables in the experiment are shown in Table 1.
 18th International Conference on Computers and Industrial Engineering 639

Table 1. Levels of Independent Variables

Variable Unit Level

1 2 3 ¢

Cutting Variables
Catting Speed (S) m/min 160 265 340
Feed Rate (f) mm/rev 0.15 0.35 0.60
Depth of Cut (D) mm 0.2 0.4 0.6 0.8

Tool variables
Tool nose Radius (r) mm 0.79 1.59
Tool Length (T) ram 48.7 56.8

Work piece variable

Work piece length (L) mm 152.4 304.8

These values were selected in order to cover the normal range of of lathe cutting operations for plain
carbon steel. Cemented carbide cutting tools equipped with throw away inserts were used. The insert
radius points are 0.79 mm and 1.59 mm, with an 80° diamond shape and a relief angle of 0°. ANSI 1018
cold drawn carbon steel rod samples of 3.8 cm diameter were used with length of 152 mm and 305 mm.
In order to perform all possible variable combinations, a total of 288 cuts were made.

4.0 SURFACE ROUGHNESS AND VIBRATION TOOL MEASUREMENTS

A Mitutoyo SurfTest 201 apparatus was used for the surface roughness measurements. The average value
(R,) was recorded as the value of surface roughness (gm). The tool has been instrumented with a triaxial
accelerometer to measure accelerations in the feeding, tangential ( to the rotating work piece) and radial
directions. Accelerations (m/s:) have been recorded and analysed with a four channels Zonic Fast Fourier
Transform (FFT) analyzer.

5.0 VIBRATION TOOL ANALYSIS

In order to study the effect of tool vibration on surface roughness, it is necessary to first analyse how tool
vibration acts on machined piece. As mentionned by Thomas [14] and Tobias [15], a variation of the
cutting force AF(t) causes the tool to deflect and dig farther into the material. Consequently the chip
thickness varies in proportion with the force variation. The force variation can be considered pmpor-
tiommal with the tool deflection x(t):

/~:(t) = ~ [ ( * x(t) (1)

where AK can be conskiered as a chip-thickness coefficient. Measurements of tool vibration have shown
that tool vibrates mainly as a one degree of freedom sys~m. Consequently, the motion equmion for the
system can be discribed as:

M.~(t) + Cx(t) + Kx(O = - ~ ( t ) (2)

640 18th International Conference on Computers and Industrial Engineering

By incorporating equation ( 1). equation (2) becomes:

M~(t) + Cx(t) + (K + AK)x(t) = 0 (3)

It is shown, therefore, that the cutting operation modifies the stiffness of the system and hence its natural
fiequency. The natural frequency of the tool while cutting is determined by the expression:

col = ~ "~/(K+ AK}/M (4)

This equation allows to compute the chip thickness coefficient AK by measuring the natural frequency
while cutting o~, and the initial natural frequency of the tool c00:

AK = 4~2 M(t012 - 2 ) (5)

The initial natural frequency of the tool (¢00) has been measured at a frequency of 2550 Hz for a short
tool and a frequency of 2140 Hz for a long tool. Since the dynamic force that is acting on the tool must
reflect the chip-thickness variation, therefore we decided to evaluate the effect of the cutting and tool
parameters using the dynamic force AF(t) as the dependant variable. This force is computed using
equation (1). The tool deflection x(t) is obtained by measuring the acceleration amplitude at the tool's
natural frequency, and then by dividing this amplitude by the square of the natural frequency e),. Finally,
the chip-thickness coefficient (AK) is computed using equation (5). Acceleration amplitudes of the tool
during machining have been recorded in three directions: feed, tangential and radial. The analysis of
recorded data has shown that the accelerationwas greatest in the tangential direction, values ranging from
13 m/s2to 601 m/s2with a mean value of 145 m/s2. Analysis of spectral curves has shown that the natural
frequencies of the tool while cutting increased from 2550Hz to values varying between 2810 Hz and 3110
Hz for a short tool and from 2140 Hz to values varying betwnen 2330 Hz and 2790 Hz for a long tool.

6.0 ANALYSIS OF VARIANCE ON DEPENDANT VARIABLES

Analysis of variance (ANOVA) was used on the collected data to investigate the main effects of cutting
speed (S), feed rate (f), depth of cut (D), tool nose radius (r), work.piece length (W) and tool length (T)
and their corresponding two and three level interaction effects on dependant variables.

6.1 Analysis of variance on surface rouglmeu

The computer ANOVA output and the calculated F ratios are shown in Table 2. For the analysis, we
selected the 0.01 level for testing the significance of main effects, two level interaction and three-level
interactieaa effects. The following three level interactions show stafisfi------~ysignificant effects on surface
roughness (p<O.01): feed rate, depth of cut and cutting speed (tDS) and feed rate and cutting speed and
tool nose radius (fSr).

6.2 AnalyJis of vartmee on tool dynami~forea

The computer ANOVA output and the calculated F ratios applied to the analysis of tangential dynamic
forces of the tool are shown in Table 3. We selected the 0.01 level for testing the sit,nificance of main
effects together with two and three level interaction effects. As indicated in Table 3, the following
two level interactions show statistically significant effects on tool dynamic forces (p<O.01): cutting
speed and tool nose radius (Sr), and cutting speed and tool length (ST). Furthermore, the following
 18th International Conference on Computers and Industrial Engineering 641

three level interaction also shows statistically significant effect on tool dynamic forces: feed rate, depth
of cut and cutting speed (fDS ~. As we are looking on the effect of vibration on surface roughness, only
common interactions between cutting parameters to surface roughness and dynamic forces are investi-
gated. These interactions are: feed rate, depth of cut and cutting speed (fDS) and cutting speed and tool
nose radius (Sr).

Table 2. ANOVA for surface roughness Table 3. ANOVA for tool dynamic force

Source df SS F Source df SS F

f 2 1233 6497 * D 3 159547 20 *

r 1 36 383* S 2 142650 27 *
S 2 4 19 * T 1 111808 42 *
2 27 142" DS 6 96694 6*
Sf 4 11 28 * ST 2 66183 12 *
Sr 2 2 12 * Sr 2 84248 16 *
Df 6 3 5*
fDS 12 3 3* fDS 12 137341 4*
fSr 4 7 18 *

Error 155 14 Error 155 413349

Total 287 1364 Tot~ 287 1968132

* p< 0.0001 *~0.0001

7.0 INTERACTIONS ANALYSIS ON DEPENDANT VARIABLES

7.1 Effectoffeed rate,depth of cut and cuttingspeed interaction(fDS) on tooldynamic force

and surface roughness.

Feed rate and depth of cut two-level interactions on tool dynamic forces have been plotted for a cutting
speed of 160 m/rain (figure 1) and 265 m/rain (figure 3). A comparaison of these figures shows that for
cutting speed level greater than 160 m/min, feed rate has no significant effect on tool dynamic force. At
a cutting speed of 160 m/min, it is observed that for a small depth of cut (lower than 0.6 mm), tool dynamic
force is reduced to winirnqm, no matter what feed rateis used. For depth of cut levels greater than 0.4
ram and at a cutting speed of 160 m/min, tool dynamic force increases as feed rate decreases.

Figures 2 and 4 show the interaction of feed rate and depth of cut on surface roughness at cutting speeds
of 160 m/rain and 265 m/min respectively. Figure 4 reveals that for cutting speed levels greater than 160
m/min, surface roughness deteriorates with feed rate while depth of cut has no effect on surface
roughness. At a cutting speed of 160 m/min (figure 2), depth of cut has no effect on surface roughness,
except at the feed rate of 0.15 mm/rev, in which case a depth of cut lower than 0.6 mm further deteriorates
the surfam~finish.
642 18lh International Conference on Computers and Industrial Engineering

Figure 1. Interaction fD for tool dynamic force Figure 2. Interaction fD for surface roughness
Cutting speed (S) = 160 m/rain Cutting speed(S) = 160 m/rain

AF (N) Ra 01m)
feedrate(0 feed rate (0
(mm/rev) (mm/rev)
340 T T

0.15
240

140
0.35
~ 0.35
40
0.6 T 0.15

0.2 0.4 0.6 0.8 0.2 0.4 0.6 0.8

Depth of cut (D) (mm) Depth of cut (D) (ram)

Figure 3. Interaction fD for tool dynamic force Figure 4. Interaction fD for surface roughness
Cutting speed (S) = 265 en/min Cutting speed (S) = 265 m/rain

~'~ 0~) Ra ~m)

feed rate (f)
(nun~v)
340
0.6

240
feed rate (0
(mm/rev)
140
0.15
2 t----t oJ5
40 0.35
0.6 - "r'" -I-
j..
"I"
.J-
T
.I-
0.15

0
0.2 0.4 0.6 0.8 0.2 0.4 0.6 0.8
Dep~ of cut (D) (ram) of cw ~ ) (,am)

7.2 Effect of cutiing #peed and tool nose radius interaction on tool dymamicforce
and surface rougimas (St).

Figure 5 shows that tool nose radius has no effect on tool dynamic force, except when operating at a
cutting speed of 160 m/min~ Tool dynamic force increases with a large tool nose radius (1.59 ram)
combined with a small cutting speed (160 m/rain).

An examination of cutting speed and tool nose radius interaction (Sr) shown in figure 6 reveals that
surface roughness is strongly affected by cutting speed when using a larger tool nose radius. At that
condition, we fmd that there is a surface roughness improvement for cutting speed levels up to 265 m/
min after which no noticeable improvement is observed. A variation in the cutting speed levels, however,
do not produce any change on surface roughness when a smaller tool nose radius is used. We conclude
 18th International Conference on Computers and Industrial Engineering 643

that the best surface finish is achieved when operating with a larger tool nose radius (here, 1.59 rnm) at
cutting speed levels equal or higher than 265 m/rain. In fact, analysis of three-level interactions also
revealed that cutting speed, tool nose radius and feed rate do interact on surface roughness. This three-
level interaction analysis has revealed that surface roughness has deteriorated when operating at a low
feed rate of 0.15 mm/rev, a low cutting speed of 160 m/rain and a large tool nose radius of 1.59 mm. This
deterioration can be attributed to the increase of the dynamic tool force. These undesirable operating
conditions happen when operating at the built-up edge range.

Figure 5. Interaction Sr for tool dynamic force Figure 6. Interaction Sr for surface roughness
AF (N) Ra (Din)

3.7
Toolnoseradius(r)
(nun) 3.5
II0
1.59 Tool nose radius (r)
3.3 (mm)
80
3.1 1.59
50
2.9
0.79
20 2.7

2.5
160 265 340 160 265 340
Cutting~ (S)(m~n) Cuuingspeed(S) (m/min)

7.3 Effectof tooldynamic force on surfaceroughness

A previous study [3] on surface roughness had shown that built-up edge formation could happen when
operating at cutting speeds lower than 265 m/rain combined with a feed rate of 0.15 mm/rev and a tool
nose radius of 1.59 ram. This result is depicted on figures 2 & 6. When operating in this range (feed rate
of0.15 m/rev, cutting speed of 160 m/min and tool nose radius of 1:59 mm), surface roughness increases
and the rate of increase is reduced when increasing the depth of cut. In the same operating range, dynamic
forces increase with depth of cut and with tool nose radius. So, it seems that the built-up edge f'ofmafion
deteriorates surface roughness and increases dynamic forces acting on the tool. By further increasing the
dynamic force that is actingon the tool,which isobtainedby increasing the depth of cut,the effectof
built-upedge formation isreduced and,therefore,the surfaceroughness isimproved, In otherranges of
o p e r a t i o n ( Cutting s p e e d greater than 160 m/rain), dylgHlfiC force has no significant effect on the
deterioration of surface roughness. In these cases, surface roughness is mainly affected by the two cutting
parameters: feed rate and tool nose radius.

8.0 CONCLUSION

The results show that the feed rate (f) and the tool nose radius (r) are the variables that produces the most
important effects on surface roughness, followed by the cuttingspeed (S). Tool vibration analysis has
revealed that two types of data are correlated to the cutting parameters: the amplitude of vibration
measured at the tool's natural frequency and the variation of this natural frequency. These data reflect
the effect of the chip variation that acts as a dynamic force which excites tool vibration. The cutting speed,
644 18th International Conference on Computers and Industrial Engineering

although highly significant as a main effect, only affects surface roughness at specific feed rate (0.15 mm/
rev), tool nose radius ( 1.59 ram) and depth of cut (lower than 0.6 mm). when lower than 265 m/rain. This
situation has been related to the built-up edge formation. Consequently, it has been shown that two
separate analysis for surface roughness must be carried out, one when operating within the built-up edge
range and the other when cutting parameters are set in order to avoid this phenomena. When operating
within the built-up range, it has been shown that depth of cut has ~ significant effect on surface roughness
and that an increase of depth of cut can help to reduce the surface roughness deterioration. Greatest
dynamic forces acting on the tool have been observed when operating within this built-up range. The
increase of dynamic forces was more significant when increasing the depth of cut. These conditions
suggest that when operating in the built-up edge range, built-up edge formation causes the deterioration
of surface roughness and increases dynamic forces acting on the tool. The effect of built-up edge
formation on the deterioration of surface roughness can be reduced by increasing depth of cul and tool
vibration. When cutting parameters are set in order to avoid the built-up edge range, tool vibration has
not a significant effect on surface roughness. In this operating range, feed rate and tool nose nose radius
explain the major part of surface roughness. The analysis of variance results revealed that the best surface
roughness condition is achieved with a low feed rate (less than 0.35 mm/rev), a large tool nose radius ( 1.59
ram) and a high cutting speed (265 m/rain and above). The results show that depth of cut (D) has not a
significant effect on surface roughness, thus indicating that a maximum removal rate can be obtained by
increasing the depth of cut without a significant change in the value of surface roughness when operating
at the optimal condition presented above.

REFERENCES
[1] Albrecht A.B., 1956, "How to secure desired surface finish in turning operations", American machinist, pp 133-136.
[2] ikanchamp Y., Mnsounav¢J.,Thomas M. and YonssefY.A., 1995, 'Modeling oflatthe dry turning operation variable's
effects on surface roughness', submitted to ASME, Journal of Engineering for IndusUy.
[3] Be_~_w_hampy., Thomas M., Youssef Y. A. and Masounave J., 1994,' Effect oflnthe dry turning operation variables
on surfaceroughness ', submittedto QualityEngineering.
[4] BeamchampY, Thomas M., Masounav¢ J and Yonssef Y.A., 1994,' Application of a full factorial design for the
development of prediction models for surface roughness in lathe turning and boring operations', Tenth international
conforonce of the Israel society for quality, Part 2, Jerusalem, pp 953- 961.
[51 Bonbekri H., Schneider M. H. and Asfour S., 1992, "Effects of some machining variables in lathe facing using
a pmfilometer to measure surface roughness", Quality Engineering, 5(2), pp 243-253.
[61 Hesngawn M., Seireg A. and L i n d ~ RA., 1976, "Surface roughness model for turning", Triboiogy international,
pp 285-289.
17] J a g D.Y.,Seitng A., 1989, "Dynamic simulation for predicting surface roughness in turning",ASME Machinery
dynamics applications and vibration control i~blems, De vol. 18 2, pp 31-36.
[81 J., 1976, 'Principles of machining by cutting, abrasion and erosion', Peter Pe~egrinns lied, Steveange,
Warsaw, 551 p.
[9] Olaen K.V., 1968, "Surface mnglmeu on tmmsd steelcomponents and the relevantmathematical analysis",The
engineer,pp 593-6O6.
ll0] Sankar, R.S., and Ommm,M.O.M., 1975, "Omractetization of numufactured surface using random function excursive
tedmique". ASIM[EJournal of Engineerin8 for Indnsl~ry,Vol. 97, pp. 190-195.
[111 Saxena J.P., 1982,' Effect of machining conditions on cutting tool vibrations', Adv. Mach. Tool Des. Manuf. Technol.,
pp 98-106.
[121 Tmmmm K., 1974, "Multi machining output multi independent variable turning research by response surface metho-
dology", InL J. Prod. Res., Vol 12 (2), pp 233-245.
[131 "lltmnas, M. and Benuchamp, Y., 1993, "Prediction of surface roughness for tuning using only controlled coifing
ilrameters ", CAD, CAM, Robo/ks and Autonomous Factories: Volume 1, Editors Jeneja, B.L., Pujexa, K.K., Sailer,
R.. TATA McGraw Hill, Dehli (India), pp. 517-526.
[14] Thomas, M., Be~_~_w=hampY., Yonssef Y.A. and Mnsommve J.,'1995, Effect of lathe dry turning parmneters oa mrface
roughness Cutting faeces and tool vibrations', submitted m ASME, Journal of Engineering for indusury.
[ISl Tobias S.A., 1965,' Machine-tool viMation', Blsckie, london, 341 p.
(16] Youssef Y.A., Be~_
_,_~hamp Y. and Thomas M., 1994 ,' Comparnison of a full factoxialexperiment to fractioanal and
Tnguchi designs in a lathe dry turning operation', Computers Ind. Eng., Vol 27, No 1-4, pp 59-62.