Evaluation of Dynamic Transients and Their Effects on Process Variables in Cutting Operations

Vibration analyses of cutting processes have been used to redefine process parameters that are required or engaged to achieve better surface integrity. Studies resulting from these findings and subsequent redesigns have majorly considered solutions to identified vibration complexities without proper consideration of the effects of dynamic and non-harmonic transients generated by these vibrations. In this paper, criticalities of cutting process variables have been investigated with particular interest on the influence of dynamic transients resulting non-conformance variability issues, which are indirectly impacted on the machine components and directly transmitted to the cutting tools, with a final destination on the workpiece. The effect of this impact on the workpiece is of critical interest to the investor, whose returns on investment is significantly dependant on the technical viability of his product for which surface finish and integrity is a cardinal requirement. Thus, the study unveils the nexus between cutting process variables and non-harmonic dynamic transients by utilizing contourized pathways as measurable mechanical energy exit points. Invariably, line traces resulting from these points were shown to connote vibration signatures on the workpiece; which implies that, as the cutting machine tends towards inoperability status, by virtue of age and frequency of deployment, the rising profile of the emergent tool signatures on the workpiece indicate the necessity for redefinitions and redesigns that must eliminate the noted non-harmonic dynamic transients.