Date of Publication :28th June 2017

Abstract: Work in this paper is primarily focused on monitoring and controlling the tool vibration using magneto-rheological damper. Magneto–rheological damper consists of MR fluid whose viscosity and shearing stress can be controlled by changing the magnetic field around it with the help of current passing through the coils wrapped around the fluid container. The study involves the characterization of MR fluid as well as vibration characterization of MR damper. Thus MR damper provides variable stiffness and better damping ability and hence better control over the process. The experimental results show that dynamic response and machining parameters (tool wear, surface roughness and cutting force) of the cutting tool system is improved to a great extent when MR damper was employed. In this paper, transmissibility approach and half-power bandwidth method were incorporated to analyse the signal amplitude ratio, the damping ratio and settling time of MR damper. In addition to this dynamic stability of the cutting tool holder was obtained with the second mode of vibration using ANSYS. With the help of MR damper, the tool vibration was reduced to a great extent which ensures the reduction in tool wear, less fluctuation in cutting force, less power consumption and hence better tool life and improved productivity.

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