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17.

Enlist the causes of vibrations in machine tool applications

Ans: -

1. Cutting force Fluctuations


• In operations like milling, the cutting force varies as the tool enters and exits the workpiece, thus
causing vibrations
• The formation of chips leads to variation in the cutting forces thus causing vibrations.
• The cutting forces can deflect the tool thus leading to vibrations.

2. Structural rigidity of the machine tool


• Insufficient structural rigidity of the machine tool can lead to vibrations at higher speeds and
feeds.
• If the excitation frequency of the cutting process coincides with the natural frequency of the
machine tool, resonance can occur, amplifying vibrations.

3. Dynamics of the machine tool


• Unbalanced components, such as spindles and pulleys, can cause vibrations.
• Worn bearing can cause vibrations.
• Improper gear meshing can cause vibrations.

4. Cutting tool factors


• Worn out cutting tools can lead to increased vibrations
• Incorrect tool geometry can cause vibrations
• Loose or improper tool clamping can cause vibrations

5. Workpiece factors
• Incorrect clamping of the workpiece can cause vibrations
• The material properties of the workpiece such as hardness and toughness affect vibrations

6. Environmental factors
• Vibrations from external sources, such as nearby machinery or traffic, can be transmitted to the
machine tool, causing vibrations.
• Temperature changes can affect the machine tool's structural rigidity and can cause vibrations.
Q18. Explain Stick Slip Phenomenon and methods for minimization of stick slip phenomenonrelated to
machine tool.

• The stick- slip phenomenon primarily occurs due to the difference between static and kinetic
friction.
• The coefficient of friction when the object is stationary (Static coefficient of friction) is greater
than the coefficient of friction when the object is sliding (Kinetic coefficient of friction).
• At the start of the movement, the force applied on the guided member should overcome the
frictional resistance corresponding to µ static.
• As soon as the guided member starts sliding, the frictional resistance decreases due to
decrease in µ.
• The excessive force applied on the member when it was stationary is released in the giving rise
to a jerk in the movement of the guided member
• This phenomenon is known as stick- slip phenomenon.

❖ Methods of minimizing stick slip phenomenon


• Applying appropriate lubricants to the sliding surfaces reduces friction and minimizes stick- slip.
• Damping of the vibrations using vibration dampers can absorb and dissipate the energy of
vibrations.
• Ensuring smooth and polished surfaces reduces friction.
• Designing components with optimal geometries can minimize stick-slip.
• Reducing the mass of moving components can reduce the force required to overcome static
friction.
• Using materials with low friction coefficients can reduce stick slip.
19. Write brief note on

I. Control systems in CNC Machines


• The control systems in a CNC machine are used for generating controlling movements which are
essential for carrying out a machining process in conformance to the technical specifications of
the part being machined.
• These systems interpret the programmed instructions and translate them into co- ordinated
movements of the machine’s axes.

A control system consists of: -

1. CNC Unit: - The brain of the machine, it processes input signals and generates control signals
2. Input devices: - Keyboard, mouse and machine control panel for program entry and machine
parameter settings.
3. Output devices: - Monitors and machine tool actuators (such as motors) to display information
and control machine functions.
4. Motion control system: - Responsible for accurate positioning and movement of the machine’s
axes.
5. Feedback devices: - Sensors (e.g., encoders, resolvers) that monitor the actual position and
velocity of the machine axes and provide feedback to the control system.

Functions of control system: -

• Reads and interprets the G-code program, which contains instructions for tool paths, speeds,
feeds, and other parameters.
• Generates precise control signals to drive the machine's motors and actuators, ensuring
accurate positioning and movement.
• Monitors feedback signals and corrects deviations if any.
• Controls tool changes, spindle speed, and feed rate
• Tracks machine status, sound alarms, and display diagnostic information.

Types of control systems: -

1. Open loop control: - Control system in which there is no feedback from the output of the
system to control the machine’s motion.
2. Closed- loop control system: - Control system where feedback signal is present to continuously
monitor the actual position and velocity and of the machine’s axes and adjust the control
signals accordingly.
3. Adaptive control: - Monitors the machining process and automatically adjusts parameters like
feed rate and spindle speed to optimize performance and prevent tool breakage.
4. Point to point control: - Controls the machine to move to specific points in sequence, without
controlling the path between points.
5. Straight line control: - Controls the machine to move in straight lines between points,
maintaining a constant feed rate.
6. Continuous path control: - Controls the machine to follow complex curved paths, often defined
by mathematical equations or CAD/CAM data.

II. Open loop control system in CNC machines

• Control system in which there is no feedback from the output of the system to control the
machine’s motion.
• There is no provision to compare the actual position and velocities of the machine’s axes with
the input command values.
• As per the program, the electric motor continues to run and it gives motion to the tool or a work
piece. But there is no monitoring of the actual displacement of machine slide. Programmed
value may be 50mm, but in actual slide movement is of 49.8mm. This difference is called as
‘error’.
• These errors are due to factors like backlash, mechanical wear, and variations in load.
• Since there is no provision of feedback in the control system, periodical adjustments are
required to compensate the errors.
• The system is simple, less expensive but also less accurate as feedback devices are not there.
• Maintenance is easy as compared to Closed loop control system.
• It is affected by factors like temperature, humidity, and vibration, which can impact the accuracy
of the machine's movements.
• Best suited for applications where high accuracy is not critical, such as simple drilling and milling
operations.

III. Closed loop control system in CNC machines

• Control system in which there is no feedback from the output of the system to control the
machine’s motion.
• Control system where there is a provision to continuously monitor and compare the actual
position and velocities of the machine’s axes with the input command value and adjust the
control signals accordingly
• In above system actual displacement of machine slide is compared with the input signal. And this
is done with the help of measuring device and the comparator unit. If any deviation is found it is
processed and then converted into controlling unit form. And the slide position is regulated until
we get the desired position.
• It is less susceptible to errors due to factors like backlash, mechanical wear and variations in the
load.
• The system is more accurate but complex and more expensive as feedback devices are there.
• Maintenance is complicated as compared to Open loop control system.
• It is not affected by factors like temperature, humidity, and vibration, which can impact the
accuracy of the machine's movements
• Best suited for applications where high accuracy is critical like complex machining tasks that
require tight tolerances and smooth surface finishes.

IV. Adaptive control in CNC machines

• Adaptive control is a self- correcting form of control.


• It has a unique ability to cope with time varying environment
• It is designed to compensate for its changing environment by monitoring its own performance
and altering some aspect of its control mechanism to achieve optimal performance.
• The adaptive control system used in CNC machines optimizes the machining process by
automatically adjusting cutting parameters based on real-time monitoring of the process.

Key components and functions: -

• Monitoring: - Sensors measure critical parameters like cutting force, tool temperature, and
spindle power.
• Optimization: - A control algorithm analyzes the measured data and determines the optimal
cutting speed and feed rate to maintain desired performance and prevent tool wear.
• Execution: - The control system adjusts the machine's parameters to implement the optimized
values.

Benefits of Adaptive control

• By optimizing cutting parameters, adaptive control can significantly increase machining


productivity.
• Reduced tool wear and increased tool life.
• Improved part quality and surface finish.
• Lower energy consumption and reduced tool costs.
Limitations of Adaptive control

• Adaptive control systems are complex to implement and require careful calibration and
maintenance.
• The initial investment in hardware and software is high.

Applications

• Milling: - Optimizing cutting parameters for different materials and cutting conditions.
• Turning: - Adjusting cutting parameters to maintain constant surface finish and tool life.
• Drilling: - Optimizing drilling speed and feed rate for different hole depths and materials.

V. System Engineering management

VI. Power utilization and tool- management

Power utilization

• Select a machine tool which has sufficient power to handle the required cutting forces and
speeds.
• Proper selection of cutting speed, feed rate, and depth of cut can significantly reduce power
consumption.
• Modern spindle drives with high efficiency and precise speed control can minimize energy
losses.
• Optimize coolant flow and temperature to reduce energy consumption.

Tool life optimization

• Choose tools with suitable materials, geometries and coatings for the specific machining
operation
• Maintain optimal cutting speeds and feeds to balance productivity and tool life.
• Effective Tool Path Programming to minimize tool movements and cutting time in order to
reduce tool wear.
• Inspect and maintain tools to prevent premature failure
• Use adaptive control systems to automatically adjust cutting parameters based on real-time
monitoring of tool wear and other factors.
• Minimize vibrations as large amount of high frequency vibrations adversely affect tool life.

VII. Design of machine tool bed


• The bed is a critical component of a machine tool which provides the foundation for all other
components and ensures accurate and precise machining operations.
• Its design plays a significant role in determining the overall performance, rigidity, and durability
of the machine tool.
Key considerations in bed design

• Rigidity: - The bed must possess sufficient rigidity to withstand the cutting forces and vibrations
generated during machining, preventing deflection and ensuring accurate positioning.
• Accuracy: - The bed should be designed to maintain precise alignment and positioning of the
machine's components, contributing to the overall accuracy of the machining process.
• Wear Resistance: - The guiding surfaces of the bed must be wear-resistant to minimize friction
and maintain accuracy over time.
• Vibration damping: - The bed should be designed to absorb and dissipate vibrations, reducing
their impact on the machining process.
• Thermal stability: - The bed should be thermally stable to minimize thermal expansion and
contraction, which can affect accuracy.
• Cross- sectional shape: - The cross-sectional shape of the bed significantly impacts its rigidity and
vibration damping properties. Common shapes include box-section, I-section, and H-section.
• Ribbing: - Ribs are added to reinforce the bed structure and improve rigidity.
• Guideways: - Precisely machined surfaces on the bed that guide the movement of sliding
components. Common types include sliding ways, roller ways, and ball ways.

Material selection

❖ Cast iron
• Widely used due to its good damping properties and machinability.
• Cast iron alloyed with elements like nickel, chromium and molybdenum are used for improving
strength and wear resistance
• Mechanite cast iron is a popular choice due to its fine-grained structure and improved
mechanical properties.

❖ Steel
• Used for welded bed structures, offering flexibility in design and fabrication.

❖ Concrete
• Used for large, heavy-duty machine tools, offering high rigidity and stability.
VIII. Recirculation ball type screw

• Recirculating ball screw assemblies are a type of power screw mechanism that utilizes rolling
elements (balls) to reduce friction and improve efficiency compared to traditional sliding-friction
power screws.

Key components

• Screw: - A threaded shaft with helical grooves.


• Nut: A threaded housing with corresponding helical grooves.
• Balls: -Rolling elements that circulate between the screw and nut threads.
• Recirculation mechanism: - A system of channels that guides the balls back to the load zone after
they have passed through the contact zone.

Working

• Recirculating ball screws operate on the principle of rolling friction, which significantly reduces
friction compared to sliding friction.
• Balls are introduced into the nut and circulate between the threads of the screw and nut.
• As the screw rotates, the balls roll along the threads, reducing friction and enabling smooth
motion.
• To ensure a continuous supply of balls, a recirculation mechanism guides the balls back to the
load zone after they have passed through the contact zone.
• To eliminate backlash and improve stiffness, the nut can be preloaded, applying a slight axial
force to the screw.

Advantages

• Smooth and precise motion due to reduced friction and the absence of stick-slip phenomena.
• High efficiency because of low friction due to rolling motion
• Longer service life due to low friction and reduced wear
• Load carrying capacity can be increased by preloading the assembly

Disadvantages

• Complex in design because of recirculation mechanism.


• Ball screws are more expensive compared to traditional power screws.
Applications

• Widely used in CNC machine tools for precise positioning of axes.


• Employed in robotic arms for accurate and smooth motion.
• Used in various automation systems for precise positioning and motion control.

Design considerations

• The thread profile must be Semi-circular or gothic to optimize load capacity and reduce friction.
• The size and number of balls influence the load capacity and stiffness of the assembly.
• Proper preloading can improve the stiffness and accuracy of the assembly.

Materials

• Screw and nut: - High-strength, low-carbon alloy steels with nitriding or hardening treatments to
improve surface hardness and wear resistance.
• Balls: - High-quality bearing steel balls.

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