Analytical and Finite Element Modelling of the Boring bar for Stability Studies

Abstract

Tool Vibration induced in boring operations not only deteriorates the surface finish of workpiece but also adversely affects tool life and produce noise during the machining operation. Thus, it is essential to suppress these unwanted vibrations. Before applying any damping technique to suppress the chatter, it is necessary to know the behavior of the conventional tool. Therefore, in this paper, a traditional boring bar is modelled as a cantilever Euler-Bernoulli beam for which the first mode of vibration is considered. In addition, simulation of the system is performed in frequency and time domain and obtained stability lobe diagrams and time domain plots respectively. Further, these results are validated with finite element model. It is observed that the results of beam theory and finite element model are in good agreement. For minimizing the vibration levels, the concept of constrained layer damping is implemented with hybrid composite material as damping layer. The resultant vibration levels of such sandwiched boring tool with hybrid composite layer have drastically reduced in comparison with conventional tool.