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International Journal on Interactive Design and Manufacturing (IJIDeM)

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20-03-2024 | Original Article

The influence of material stiffness and damping on machining stability in boring tool–workpiece systems using finite element simulation to implement digital twin

Authors: Saravanamurugan Sundaram, Fawas Puthenveetil, Viswajith S. Nair, Rameshkumar Krishnaswamy

Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) | Issue 9/2024

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Abstract

The article delves into the critical role of material stiffness and damping in machining stability, particularly in boring tool–workpiece systems. It utilizes finite element simulation to develop a digital twin framework, enabling real-time monitoring and prediction of machining stability. The study highlights the significant influence of workpiece stiffness on chatter stability, demonstrating that moderately high stiffness workpieces can significantly reduce the depth of cut required for stable machining. The research combines analytical, computational, and experimental methods to validate its findings, showcasing the potential of digital twin technology in enhancing machining performance and efficiency.

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Abstract

Regenerative chatter is a prominent form of vibration in any machining process caused by the waviness of the workpiece surface. During internal turning processes, regenerative chatter constitutes a significant concern due to the highly flexible nature of boring bars and workpieces. As a result, the surface finish is poor, tool wear is accelerated, and machining at a high depth of cut is challenging. Typically, stability lobe diagrams (SLDs), plots of spindle speeds versus depth of cuts, are employed to select stable machining parameters. In the present work, a numerical linear stability analysis of a two-degree-of-freedom finite element model of a boring tool–workpiece system is carried out in the frequency domain to construct SLDs that are utilized to investigate how changing dynamics of the workpiece affect machining stability. The numerical model is validated using an analytical model, and the results of both models are found to be in agreement. Moreover, the results show that the depth of cut of a tool–workpiece system with moderately low and high workpiece stiffness is 11.8% and 16.2% lower than that of a single degree-of-freedom (DOF) system that does not take the workpiece into account. The SLDs of two DOF systems with workpieces of high and very high stiffness are observed to overlap with that of a single DOF system. It is also inferred that the damping ratio of the workpiece has no significant effect on the stability lobes. The machining experiments are conducted on a boring tool–workpiece system, and it is found that the experimental results align with the analytical and numerical findings. Additionally, a digital twin framework based on the computational model is suggested to facilitate the real-time monitoring and optimization of boring processes.

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Title: The influence of material stiffness and damping on machining stability in boring tool–workpiece systems using finite element simulation to implement digital twin
Authors: Saravanamurugan Sundaram
Fawas Puthenveetil
Viswajith S. Nair
Rameshkumar Krishnaswamy
Publication date: 20-03-2024
Publisher: Springer Paris
Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) / Issue 9/2024
Print ISSN: 1955-2513
Electronic ISSN: 1955-2505
DOI: https://doi.org/10.1007/s12008-024-01757-7

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The influence of material stiffness and damping on machining stability in boring tool–workpiece systems using finite element simulation to implement digital twin

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Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

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