FEA BASED MODELING OF MAGNETO RHEOLOGICAL DAMPER TO CONTROL VIBRATIONS DURING CONTOUR MILLING

Mechanical Engineering

In determining the vibrations and deflections occurring during end milling process, the modeling and structural behavior plays an important role. The geometry of an end mill tool is complex. To overcome the complexity of the analysis, a simple beam model is considered. In this work the modeling of structure of an end mill is carried out and by the application of Finite Element Methods. The Static analysis has been performed in order to determine the deflection and suppress the vibration of end mill cutter so that the work piece will not have waviness on the surface, leading to minimization of chatter encountered during machining. The effect of dynamic response of the end mill tool is studied with and without the application of MR damper. Metal cutting operation involves interaction of cutting forces of the tool with the regenerative forces of the material of work piece during metal cutting. To control the end mill tool vibration and suppress the chatter, the method incorporates the unique features of a magnetic-rheological fluid, utilizes the damper input current to modify the magnetic field inside the coil of the damper and increase the variable stiffness and produce damping effect. In this work, the identification of chatter is done by means of the magnetic-rheological fluid. The different metal cutting parameters are considered in experimental work and results are compared with and without the application of magnetic-rheological damping effect. The results show the enhancement of quality of the machined surface, reduction of deflection of the end mill tool and decrease in the chatter marks on work piece by producing magnetic-rheological damping to the end mill tool. The damper input current is varied from 0 to 2 Amps, which modifies the rheological damping effect to the end mill at different machining parameters and the results are validated with finite element analysis software ANSYS 11.0. It is inferred that experimental results are in good agreement with results in ANSYS. It is seen that ANSYS can predict the value of deflection very accurately with a variation of 3% to 5% of the actual value, indicating the validity that ANSYS for the analysis of both H.S.Steel and Carbide cutter in case of four flute end milling under different machining conditions. The effectiveness of the MR damper is used in an end milling operation and it is successfully established in the project.

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