Modeling of quality characteristics at the finishing operations of workpieces using vibration resistance indicators
DOI:
https://doi.org/10.15276/opu.1.71.2025.01Keywords:
finishing operations, surface quality, vibration resistance, amplitude, oscillation periodAbstract
The paper addresses the determination of the qualitative characteristics of machined workpieces surfaces in finish operations based on the vibration resistance indicators of the “machine – fixture – tool –workpiece” system. After finishing, the surface of the workpieces is never perfectly smooth, but always exhibits microscopic irregularities that form roughness and microdefects. In the operations preceding grinding, surface roughness influences stress concentrations, vibration activity, and the formation of thermal defects that, under the thermomechanical phenomena that accompany finish machining, cause burns, cracks, and chipping of the workpiece. The cutting process generates intense vibrations in the tool, the workpiece, the machine itself, and the chip removed. The stated problem and its proposed solution focus on studying the oscillations of the workpiece surface under the action of cutting forces. Calculation results make it possible to evaluate the vibration resistance of the entire “machine – fixture – tool –workpiece” system by matching oscillation amplitudes and periods. The proposed method for identifying the resonance zones of the system’s force oscillations enables control of the grinding process when using a specific tool. This control is achieved by selecting cutting speeds, determining optimal cut depths, or adjusting the workpiece mass. The method is recommended for implementation in the practice of optimizing grinding processes for materials prone to thermal defects. Experimental validation of the model was carried out on workpiecess made of 102Cr6 and X12CrNiTi18-9 steels and titanium alloys, confirming prediction accuracy within 10% deviation. The results obtained have allowed the development of recommendations for choosing grinding regimes and parameters, as well as fixture and tool design, to ensure process stability and reduce the occurrence of thermal and vibration-induced defects.
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