PREDICTION OF VIBRATION DURING TURNING OF SAE 5160 STEEL

Abstract

Abstract. The manufacturing industry's fierce competition has resulted in a never-ending search for cost-effective cutting operations. Faster machining and shorter cycle times are thus, required for increased productivity. This study presents an analysis and optimization of the vibration induced in SAE 5160 steel during a turning operation. The effect of cutting conditions comparatively, cutting speed, feed rate, and depth of cut on resultant vibration were studied on M300 Harrison Lathe in a Dry Turning environment using SAE 5160 Steel as workpiece and HSS cutting tool. The design of the experiment was implemented by utilizing the 23 factorial design method with confirmatory tests to verify the findings. The study indicated the depth of cut as the principal factor on the resultant vibration while turning SAE 5160 Steel. The R2 value for vibration was 97.13% which showed that the model fitted the data well. The average percentage error for predicting the vibration was which fell within the range of and thus, renders its corresponding model valid for subsequent predictions of vibration. The optimal cutting conditions for minimum vibration were obtained at low cutting speed (40 m/min), low feed rate (0.0.1 mm/rev), and low depth of cut (0.5 mm).