Investigation of the effect of Chip Slenderness Ratio and Cutting Tool Approach Angle on Vibration Amplitudes and Chip Morphology

Abstract

Machinability, especially turning process, is a significant manufacturing method, but the vibrations, comeabout the real mechanism of the operation, make difficulties. Unnumbered parameters influence theprocess outcomes such as machined face raggedness, chip morphology, and vibration amplitudes. In thepresent research, the effect of tool approaching inclination and chip slenderness ratio (CSR) on thedeflection amplitudes, StDev in vibrations, and chip morphology were investigated. For this purpose, 15o,30o, and 45oapproaching inclinations, 1, 3, 5, 10, and 15 CSR also depending on CSR values 0,1 mm/rev,0,15 mm/rev, 0,45 mm/rev, and 0,5 mm/rev feed rates, 0,5 mm, 1 mm, 1,5 mm, and 2,25 mm cuttingdepths were chosen. It was investigated that according to both vibration amplitudes and chip morphologycriterion, the most appropriate cutting tool approach angle was 30o, and CSR values were 10 and 15.Besides, as the cutter approaching inclination progress, the deflection magnitudes in the X (removingdeepness) direction were deteriorated, but at small CSR values, they were increased. The optimum feedrates were to be 0,1 mm/rev and 0,15 mm/rev, but the influence of the cutting depth showed differencesdepending on the values of the selected feed rates. Surface quality was improved at 30oand 45oapproachangles, 0,1mm/rev and 0,15 mm/rev proceeding speeds and10 and 15 CSR valences. The chips in lamellasform, without sharp deformation breaks and serration generations were perceived at 30oapproachinginclination, 0,1 mm/rev and 0,15 mm/rev proceeding speeds also at 10 and 15 CSR values.