sandwiched between main steel boring bar and aluminium tube, known to be constrained viscoelastic layer damper (CVLD), is designed and developed in order to reduce the vibration produced during the machining operations. The low density aluminium tube and natural rubber as viscoelastic layer are used in the boring bar to increase its natural frequency and damping property respectively. The finite element simulation of boring bar with and without CVLD are carried out using ANSYS and the results are used to develop a model to predict the influence of thickness of viscoelastic layer and aluminium tube on natural frequency of boring bar using full factorial design of experiments (DOE) and regression analysis. The DOE and regression analysis, carried using Minitab package, provides optimum thickness of viscoelastic layer and aluminium tube. These optimum thickness values are used to fabricate CVLD and its effectiveness to control boring bar vibration is tested by conducting machining experiments. The surface roughness of the machined components is also measured and the results show that the boring bar with CVLD is more efficient than conventional boring bar in controlling vibrations during machining. Moreover, stability lobes, which are plots of spindle speed vs. depth of cut of a machining process, are also constructed. Stability lobes indicate that the machining stability may be improved by 15 % by using boring bar with CVLD.
V. V Krishna, Saravanamurugan, S., P Kishore, S., Yedhu, K. J., Iswar, G. K., and Shanmugasundaram A., “Vibration control in boring process using a constrained viscoelastic layer damper”, IOP Conference Series Materials science and Engineering (2nd International Conference on Materials and Manufacturing and Machining for Industry – 4.0, ICMMM 2020), vol. 1059. IOP Publishing, Bannari Amman Institute of Technology, October 9 – 10, 2020, Sathyamangalam, 2021.