Experimental evaluation of critical axial depth of cut with magneto rheological damping in end milling process

An end milling process is widely used in fabrication of complex contours and shape parts at high spindle speeds. Many researchers try to investigate one of important aspect, which come across during machining is the self exited chatter vibration which causes severe damage of the tool and quality of the machined surface. The present work is focused on the Magneto-Rheological Damping effect on stability of chatter in an end milling process during machining. The end mill cutter was modeled as a rotating Euler Beam with an attached MR Damper as bar element and its first five modes of vibrations are considered. The stability analysis has been carried out by considering the two degrees of freedom of the model. End Mill cutter considered as a uniform rotating cantilever beam with attached active Magneto-Rheological Damper to it was investigated. The Dynamic force of an Magneto-Rheological Damper is generated by varying damper Input current The cutter is discrtized by using finite element Method. The governing equation of motion of the end mill cutter was derived by using D Alembert’s Principle. The results obtained from the simulation reveal that how the allocation of Magneto-Rheological Damper affects the dynamic properties of the end mill cutter. In this paper an attempt has been made to utilize the remarkable dynamic properties of MR fluid to control the vibrations and suppress the chatter. The natural and chatter frequencies of the end mill cutter under the influence of Magneto-Rheological damping has been found at different machining parameters Such as Depth of cut, Spindle speed, and Feed rate. In the present paper we have investigated the presented chatter, the effect of Magneto Rheological damping on stability limits by considering the different machining parameters. A series of experiments have been performed and evaluated the chatter frequency and the limit of axial depth during end milling. The acceleration of the four Flute HSS End mill cutters was measured during the machining of aluminum work piece. Power spectral analysis have been carried out to evaluate the dynamic characteristics of the end mill cutter under the influence of Magneto Rheological Damping by considering different machining parameters.