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Application of smart fluid to control vibration in metal cutting: a review

S. Sarath (Department of Mechanical Engineering, St. Thomas College of Engineering and Technology, Chengannur, India)
P. Sam Paul (Department of Mechanical Engineering, Karunya Institute of Technology and Sciences, Coimbatore, India)

World Journal of Engineering

ISSN: 1708-5284

Article publication date: 3 February 2021

Issue publication date: 28 May 2021

176

Abstract

Purpose

A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of the service period of the cutting tool while machining. It is significant to provide a corresponding real-time varying damping to control this chatter, which directly influences accuracy and quality of productivity. This paper aims to review the literature related to the application of smart fluid to control vibration in metal cutting and also focused on the challenges involved in the implementation of active control system during machining process.

Design/methodology/approach

Smart dampers, which are used as semi-active and active dampers in metal cutting, were reviewed and the research studies carried out in the field of the magnetorheological (MR) damper were concentrated. In smart materials, MR fluids possess some disadvantages because of their sedimentation of iron particles, leakage and slow response time. To overcome these drawbacks, new MR materials such as MR foam, MR elastomers, MR gels and MR plastomers have been recommended and suggested. This review intents to throw light into available literature which exclusively deals with controlling chatter in metal cutting with the help of MR damping methods.

Findings

Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. In the past, many researchers have attempted to implement MR damper in metal cutting to control vibration and were successful. Various methods with the help of MR fluid are illustrated.

Research limitations/implications

A new cutting tool is always well-defined and sharp at the onset of metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of service period of cutting tool while machining. Application of MR damper along with the working methodology in metal cutting is presented, challenges met are analyzed and a scope for development is reviewed.

Practical implications

This study provides corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity. Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration.

Social implications

This study attempts to implement smart damper in metal cutting to control vibrations.

Originality/value

It is significant to provide corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity.

Keywords

Acknowledgements

The authors are grateful to the Department of Mechanical Engineering, Karunya Institute of Technology and Sciences for facilitating this research work. Also no funding grant was received for supporting this research work.

Citation

Sarath, S. and Paul, P.S. (2021), "Application of smart fluid to control vibration in metal cutting: a review", World Journal of Engineering, Vol. 18 No. 3, pp. 458-479. https://doi.org/10.1108/WJE-06-2020-0232

Publisher

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Emerald Publishing Limited

Copyright © 2020, Emerald Publishing Limited

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