A review on vibration mitigation of boring bar using passive damping techniques

IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 138
A REVIEW ON VIBRATION MITIGATION OF BORING BAR USING
PASSIVE DAMPING TECHNIQUES
Pooja J. Waghmare1
, R. V. Patil2
, G.S. Waghmare3
1
P.G.Student, Department of Mechanical Engineering, Sinhgad Institute of Technology & Science, Maharashtra,
India
2
Assistant Professor, Department of Mechanical Engineering , Sinhgad Institute of Technology & Science,
Maharashtra, India
3
Assistant Professor, Department of Mechanical Engineering , Sinhgad Institute of Technology & Science,
Maharashtra, India
Abstract
Work piece and tool vibration control has been a subject of primary importance in manufacturing industry. High slenderness
ratio is a reason for boring bar to be subjected to high amount of vibrations that accelerate the tool wear affecting the tool life,
higher noise level and increased deviations. This review focuses on various damping techniques such as passive damping systems
using particle impact damping and Magneto-Rheological (MR) fluid for vibration attenuation purpose. This also introduces the
mechanics of boring operation that affects the tool wear, surface roughness, noise and hence affects the productivity. This review
compares the results of boring bar using passive damping and the conventional tool on the basis of modal analysis of vibrating
structure, and the test results. This paper explains the vibration behavior of a conventional boring bar and a boring bar using
passive techniques for vibration reduction.
Keywords: Damping particles, vibrations, Magneto-Rheological fluid (MR).
--------------------------------------------------------------------***-----------------------------------------------------------------
1. INTRODUCTION
The vibration between a tool and a workpiece is an
important issue in machining operations, as it may
deteriorate the workpiece surface quality, lower the
productivity, and shorten the tool life. Boring process is an
internal turning process in which the boring tool advances
through an already drilled hole to increase its surface finish.
Boring operation is usually prone to large amount of
vibrations as the boring tool is a slender component.
The boring bars have low inherent stiffness due to high
length-to diameter ratio and hence are more prone to
vibration. Cutting speed, feed and depth of cut are the
parameters affecting the vibrational behavior of any
vibrating structure. Vibration in boring operations is usually
inevitable. They are unavoidable in machining, but their
intensity levels can be controlled by suitable damping
mechanisms, either active or passive. Even though active
methods are more effective than passive methods,
complexity in design and high external power consumption
make it very expensive. Passive suppression mechanisms
are simple in construction, low cost, and do not need
external energy. Tool tip of the boring bar is the place where
vibrations will occur the most and are of major concern as it
is the cutting zone of the process.
The vibration attenuation improves the stiffness of boring
bar. By using passive damping techniques we can control
vibrations of the tool. For this purpose we use particle
damping and MR fluid techniques.
An innovative vibration suppression method based on a
magneto-rheological (MR) fluid-controlled boring bar for
vibration suppression can change stiffness of boring bar.
The stiffness of vibrating structure can be adjusted using
MR-fluid controlled boring bar. Various particles like
copper, silicon, lead, steel, rubber, lead carbide powder etc
can be used as damping material to attenuate the vibrations
which can increase the damping capability. It converts the
kinetic energy of boring bar to heat wherein in other
conventional operations internal strain energy is converted
into heat. This is how higher amount of damping is achieved
in this technique of vibration reduction.
Particle damping is remarkably effective in vibration control
of boring bar. A passive damping technique is used for the
boring tool design. It increases the damping ability of the
boring bar in terms of damping ratio by reducing large
amount of vibrations of the boring tool retaining the
stiffness of the boring bar within acceptable values thereby
maintaining the strength of boring bar.

_______________________________________________________________________________________
Fig 1: Schematic diagram of the boring bar [8]
2. LITERATURE REVIEW
M. Senthil kumar et al. [1] 2011 worked on particle
damping technique for the control of vibrations in boring
bar. He investigated the efficiency of particle damping in
vibration attenuation of boring bar using damping particles
like copper and lead. In this regard, Boring bar is drilled to
have a longitudinal hole in which damping particles were
embedded. Experimental investigations were carried out to
find out the settling time of boring bar for different particles
by giving an impact pulse by an impact hammer to the bar
held as a cantilever beam. Damping performances of these
particles having various sizes were observed and compared
.Natural frequencies of the solid boring bar acting as a beam
were compared with those of the drilled boring bar.
Displacement – time plots of boring bar without damping
particles were compared with the plots with damping
particles filled upto 100% volumetric packing ratio.
A set of particles yielding the best result of vibration control
was determined. The dependency of the amount of damping
and the frequency at which maximum damping occurs on
the size of particles revealed that particles can be designed
to control the vibrations in boring bar.
C. V. Biju et al. [2] focused on investigation into the effect
of passive damping technique using damping particles on
surface topography when boring operation is being
processed. For this purpose they used a particle damping
method called the novel method, for vibration control during
boring process. They modeled the boring bars without cavity
and with cavity and analyzed using Ansys. Spherical steel
particles were used as damping particles in a cavity near
machining end of the designed boring bar. Damping
characteristics of the boring bar were evaluated for varying
sizes and volumetric ratios of damping particles using
impact and shaker tests and results were included. Results of
experimentation in terms of surface roughness and chatter
marks were analyzed and the results showed an
improvement of bore quality with particle impact damping
as compared with a boring bar without PID.
Shaker tests revealed that 3.17 mm sized steel damping
particles with 50% volume fraction reduce the amplitude
response of boring bar. They showed that the transfer of
momentum from the vibratory system to the damping
particles and the energy dissipation caused by collision
between the particles and cavity reduce the self-excited
vibration of boring bar thereby improving the stability of
boring operation.
B. Moetakef-Imani et al. [3] presented the dynamic
simulation of boring process. They presented a model for
this simulation. They studied the causes of vibration and
vibrational behavior of boring bar for certain cutting
conditions and revealed that boring bar is easily subjected to
vibrations because of its large slenderness ratio. They used
B-spline parametric curves to simulate different tool
geometries with a single approach. Euler-Bernoulli Beam
theory was used for boring bar modeling. They stated that
the structure comprising of lathe machine, boring tool and
the work-piece undergo excessive vibrations under certain
conditions.
Zhehe Yao et al. [4] worked on chatter suppression by
parametric excitation. In this study, the effect of parametric
excitation on a van der Pol–Duffing oscillator with a time
delay feedback was studied using the averaging method.
They validated the effect of parametric excitation on chatter
suppression through the cutting experiments using Magneto-
Rheological (MR) fluid-controlled boring bar. The effect of
parametric excitation on the self-excited vibration system
was studied regardless of the generation mechanisms of the
self-excited vibration. The regenerative effect is the most
common effect that generates chatter in the machining
processes. Therefore, they studied the regenerative effect for
the stability analysis of the cutting vibration system.
Parametric excitation effects on chatter suppression were
investigated by experimental validation and theoretical
analysis. The cutting experiments using magneto-
rheological fluid controlled boring bar showed remarkable
effects on chatter suppression.
Henrik Akesson et al. [5] concentrated on studying the
various clamping conditions of boring tool. They worked on
the effect of different clamping properties on the dynamic
properties of clamped boring bars. They discussed about
Euler Bernoulli modeling of clamped boring bar with
emphasis on the modeling of the clamping conditions.
Experimental investigation results show variation in
dynamic characteristics of boring bar as per the changes in
the clamping positions of boring bar. is investigated
experimentally. Standard and modified boring bars are
considered. The influence of standard coupling housings
with different number of clamping screws, different
clamping screw diameters, different screw tightening
torques, on eigen frequency values and its mode shapes
orientation in cutting speed, cutting depth plane was
calculated. Deqing Mei et al. [6] proposed an MR fluid-
controlled chatter suppressing boring Bar. They established
a dynamic model of an MR fluid-controlled boring bar
based on an Euler–Bernoulli beam model. FEM analysis

_______________________________________________________________________________________
was applied for designing the magnetic field. They analyzed
the regions of operating stability using the dynamic beam
model, and concluded that it can be used suppress the
chatter by adjusting the damping and natural frequency of
the system. Experimental results regarding the vibrations at
the structure’s tip in different spindle speeds validated the
model and demonstrated chatter suppression in a boring
process and reduced the chatter.
S. Devaraj et al. [7] proposed fine particle impact damping
method in boring operation for surface quality enrichment of
the workpiece. Damping to suppress the vibrations was
provided by embedding fine particles within small hole of a
vibrating structure. They performed experimental
investigation for the surface roughness measurement of
workpieces. using Copper, Aluminium, Zinc and Silicon
particles but having different densities. The results they
obtained proved that the usage of silicon and zinc particles
shows less damping capability when compared to the
damping capabilities of the boring tool using Copper and
Aluminium particles. and thus it revealed that the surface
finish value of the workpiece can be improved using particle
impact damping.
Pranali Khatake et al. [8] introduced a vibration attenuation
technique for boring bar through the implementation of
passive damper. They used damping particles within the
boring bar and experimental investigation was undertaken to
observe the surface finish of specimen using different
overhang lengths of boring bar during operation. The results
proved that the chatter of the tool is suppressed at a larger
amount which means the self excited vibrations of the
boring tool are reduced..
Steven E. Olson et al. [9] established An analytical particle
damping model. They did an analytical evaluation of the
particle damper. They utilized the particle dynamics method
based on the kinematics of particle damping, involving shear
friction between the particles and contacting areas and the
dissipation of energy in the form of heat of the particle
material. Interaction forces between the individual particles
and the cavity walls are calculated based on force–
displacement relations. Application of the model has been
demonstrated by simulating laboratory testing of a
cantilevered beam.
Zhiwei Xu et al. [10] investigated a structure in which
damping particles were embedded in the horizontal hole
drilled in the vibrating structure. They concentrated on the
study of shear of the boring bar and its effects on the
damping capability of the structure. They presented an
analytical model to analyze the effect of particle damping
on vibration behavior of boring bar. They used different
volumetric ratios of particles and also different types of
particles and their various sizes to observe the damping
effect of each and to suggest a good damping material for
better vibration reduction. The passive damping using
damping particles is proved to be effective. Although it is
non-linear, it can give a strong energy dissipation rate.
3. SUMMARY
This review paper reveals that passive damping techniques
by using Magneto-Rheological fluid (MR) and damping
particles like copper, lead, silicon, rubber etc. can suppress
the vibrations during boring operation to the desired amount.
Particle damping is a better passive damping technique
which can retain its stiffness within permissible limits even
after the geometry changes of the boring tool. This proves to
be a simpler and effective method of vibration reduction.
This can be used over a wide range of temperatures and
frequencies and shows a wide scope of applications in
machining industries. This has investigated the damping
enhancement method with particulate materials like
damping particles and MR fluid. This suggests that the
Particles and MR fluid can be designed to achieve
mitigation of vibration. The review shows a greater damping
capability enhancement in comparison with the conventional
tool.
ACKNOWLEDGEMENTS
I am very thankful to my project guide Prof. R.V. Patil and
G. S. Waghmare, Assistant professor, Mechanical
Engineering Department, Sinhgad Institute of Technology
and Science, Narhe, Pune, for his continuous support and
encouragement in completing this work.
REFERENCES
[1]. M. S. Kumar, K. M. Mohanasundaram and B.
Sathishkumar, A case study on vibration control in a boring
bar using particle damping, International Journal of
Engineering, Science and Technology, 2011, 3 (8), pp. 177-
184.
[2]. Kanase Sandip S1,Patil Jaydeep S2 ,Jadhav Sainand
M3, Improvement Of Ra Value Of Boring Operation Using
Passive Damper, The International Journal Of Engineering
And Science (IJES), 2013, 2(7),pp. 103-108.
[3]. B. Moetakef-Imani , N.Z. Yussefian, Dynamic
simulation of boring process, International Journal of
Machine Tools & Manufacture, 2009, 49,pp.1096–1103.
[4]. Zhehe Yao, Deqing Mei , Zichen Chen, Chatter
suppression by parametric excitation: Model and
experiments, Journal of Sound and Vibration, 2011,330,pp
2995–3005.
[5]. Henrik Akesson, Tatiana Smirnova, Lars Hakansson,
Analysis of dynamic properties of boring bars concerning
different clamping conditions, Mechanical Systems and
Signal Processing, 2009, 23, pp. 2629-2647.
[6]. Deqing Mei, Tianrong Kong, Albert J. Shih, Zichen
Chen, Magneto-rheological fluid-controlled boring bar for
chatter suppression, journal of materials processing
technology,2009, 209, 1861–1870.
[7]. S. Devaraj1, D. Shivalingappa, Channankaiah, Rajesh S
Jangaler4, Surface Quality Enrichment Using Fine Particle
Impact Damper In Boring Operations, International Journal
of Research in Engineering and Technology, 2014, 03(02),
pp.531-535.

_______________________________________________________________________________________
[8]. Pranali Khatake1, P. T. Nitnaware, Vibration mitigation
using passive damper in machining, International Journal of
Modern Engineering Research (IJMER), 2013, 3( 6), pp-
3649-3652.
[9]. Steven E. Olson, An analytical particle damping model,
Journal of Sound and Vibration 264 (2003) 1155–1166.
[10]. Zhiwei Xua, Michael Yu Wangb, Tianning Chenc,
Particle damping for passive vibration suppression:
numerical modeling and experimental investigation, Journal
of Sound and Vibration, 2009, 207, pp. 1097–1120.

A review on vibration mitigation of boring bar using passive damping techniques

More Related Content

What's hot (20)

Viewers also liked (8)

Similar to A review on vibration mitigation of boring bar using passive damping techniques (20)

More from eSAT Journals (20)

Recently uploaded (20)

A review on vibration mitigation of boring bar using passive damping techniques