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Research Papers

Microtexture Generation Using Controlled Chatter Machining in Ultraprecision Diamond Turning

[+] Author and Article Information
Syed Adnan Ahmed

School of Mechanical
and Aerospace Engineering,
Nanyang Technological University,
Research Room 2,
Block N3, B3-01a,
50 Nanyang Avenue,
639798, Singapore
e-mail: ahme0006@e.ntu.edu.sg

Jeong Hoon Ko

Singapore Institute of Manufacturing Technology,
A*STAR,
71 Nanyang Drive SIMTech,
638075, Singapore
e-mail: jhko@SIMTech.a-star.edu.sg

Sathyan Subbiah

Department of Mechanical Engineering,
Indian Institute of Technology Madras,
Chennai 600036, India
e-mail: sathyans@iitm.ac.in

Swee Hock Yeo

School of Mechanical
and Aerospace Engineering,
Nanyang Technological University,
Research Room 2, Block N3-02b-52,
50 Nanyang Avenue,
639798, Singapore
e-mail: MSHYEO@ntu.edu.sg

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received August 17, 2014; final manuscript received January 12, 2015; published online February 20, 2015. Assoc. Editor: Gracious Ngaile.

J. Micro Nano-Manuf 3(2), 021002 (Jun 01, 2015) (9 pages) Paper No: JMNM-14-1058; doi: 10.1115/1.4029610 History: Received August 17, 2014; Revised January 12, 2015; Online February 20, 2015

This paper describes a new method of microtexture generation in precision machining through self-excited vibrations of a diamond cutting tool. Conventionally, a cutting tool vibration or chatter is detrimental to the quality of the machined surface. In this study, an attempt is made to use the cutting tool's self-excited vibration during a cutting beneficially to generate microtextures. This approach is named as “controlled chatter machining (CCM).” Modal analysis is first performed to study the dynamic behavior of the cutting tool. Turning processes are then conducted by varying the tool holder length as a means to control vibration. The experimental results indicate that the self-excited diamond cutting tool can generate microtextures of various shapes, which depend on the cutting tool shank, cutting speed, feed, and cutting depth. The potential application of this proposed technique is to create microtextures in microchannels and microcavities to be used in mass and heat transfer applications.

Copyright © 2015 by ASME
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Figures

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Fig. 1

Experimental setup on UP machine (Nanoform 200): (a) normal diamond turning where tool was held rigidly and (b) CCM condition where tool tip is excited by varying the tool shank length

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Fig. 2

Workpiece Al-6061 circular disk that shows the 2 mm width for CCM texturing at (a)–(d) varying distance from workpiece center

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Fig. 3

DAQ setup for cutting force and vibration signal

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Fig. 4

FEM model of the cutting tool shank attached at dynamometer

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Fig. 5

Schematic of tool shank, showing overhang length, and cutting directions

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Fig. 6

FEM modal analysis, natural frequencies, and mode shapes: (a) front view: first vibration mode (cutting direction, f1 = 1834 Hz) and (b) top view: second vibration mode (feed direction, f2 = 1878 Hz)

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Fig. 7

3D surface texture at feed rate = 20 μm/rev, DOC = 20 μm with varying cutting speed as (a) Vc = 138 m/min, (b) Vc = 120 m/min, (c) Vc = 105 m/min, and (d) Vc = 62.8 m/min

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Fig. 8

2D surface profile of diamond turned surface at Vc = 105 m/min: (a) trace measured in cutting direction with a peak–peak of 300 μm and (b) trace measured in feed direction with a peak–peak of 140 μm

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Fig. 9

Diamond tool forces comparison between normal diamond turning and CCM for eight samples at four machining conditions for sample “A,” “B,” “C,” and “D” (a) cutting forces and (b) thrust forces

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Fig. 10

Typical plot of measured forces for sample B during CCM experiments. (a) Cutting force plot and (b) thrust force plot.

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Fig. 11

Frequency spectrum plot of CCM machining, Vc = 105 m/min, feed = 20 μm/rev, DOC = 20 μm: (a) cutting forces and (b) feed forces

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Fig. 12

Accelerometer vibration signal for normal diamond turning condition

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Fig. 13

Accelerometer vibration signal for CCM

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Fig. 14

FFT plot of accelerometer signal for CCM

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Fig. 15

Amplitude–frequency plot for accelerometer vibration signal for CCM

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Fig. 16

Amplitude–frequency plot of numerical model shows the maximum amplitude in of cutting tool in cutting direction (peak–peak amplitude = 300μm)

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Fig. 17

Surface profile plot for different machining conditions mentioned below the individual plot

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