Vibrations are a common problem in CNC turning operations, affecting the machine tool's overall performance and productivity. The geometrical accuracy and surface quality are reduced as a result of repeated vibrations, reducing tool life. Vibrations can now be sensed and responded, thanks to new advancements in electronic technology. The goal of this research work is to use a 3D accelerometer(sensor) to measure vibrations and determine the value of vibration and its causes by analyzing data on specific axes to take corrective action. Collecting vibration data while doing turning operation was needed to understand the impact of vibrations on Tool life & surface roughness. To capture vibration on the tool holder while turning, a 3D accelerometer (sensor) was attached or mounted on tool holder. The sensor attached to tool holder is connected to Arduino UNO, Arduino is connected to laptop. With the help of software and the Programme we can get the live reading of vibration while doing turning operation. Thus, real-time data on vibrations while turning will be available for analysis, with the use of electronic technology. After determining the vibration data the causes of vibrations, will be known to us. Then by variation in machining process parameters and reducing the causes of vibrations, we can improve the tool performance and quality of machining.

Keywords: CNC Turning, Vibrations, Surface quality, 3D Accelerometers, Machining parameters, Sensors.

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1. Zhao Y, Zhao Y, Liang S, Zhou G. A high performance sensor for triaxial cutting force measurement in turning. Sensors (Switzerland). 2015 Apr 3;15(4):7969–84.
2. American Society of Mechanical Engineers, IEEE International Conference on Service-Oriented Computing and Applications, IEEE International Conference on Advanced Intelligent Mechatronics (Busan) ; 2015.07.07-11.
3. Qehaja N, Jakupi K, Bunjaku A, Bruçi M, Osmani H. Effect of machining parameters and machining time on surface roughness in dry turning process. Procedia Eng. 2015;100(January):135–40.
4. Patil AS, Sunnapwar VK, Bhole KS, More YS. Experimental investigation and fuzzy TOPSIS optimisation of Ti6Al4V finish milling. Adv Mater Process Technol [Internet]. 2021;00(00):1–24. Available from: https://doi.org/10.1080/2374068X.2021.1971002
5. Tlusty J, Andrews GC. A Critical Review of Sensors for Unmanned Machining. CIRP Ann - Manuf Technol. 1983;32(2):563–72.
6. Yaldiz S, Ünsaçar F, Saǧlam H, Işik H. Design, development and testing of a four-component milling dynamometer for the measurement of cutting force and torque. Mech Syst Signal Process. 2007;21(3):1499–511.
7. Ramachandran KA/ L. DESIGN AND DEVELOPMENT OF SMART CUTTING TOOL. Available from: http://www.researchgate.net/publication/284936318
8. Miroslav RĆ, Predrag DĆ, Predrag JĆ. Experimental Determination of Cutting Force By Longitudinal Turning of C60E Steel. 2006;2(August 2017):113–9.
9. Hasibuzzaman M, Shufian A, Shefa RK, Raihan R, Ghosh J, Sarker A. Vibration Measurement Analysis Using Arduino Based Accelerometer. 2020 IEEE Reg 10 Symp TENSYMP 2020. 2020;(June):508–12.
10. Teti R, Jemielniak K, O’Donnell G, Dornfeld D. Advanced monitoring of machining operations. CIRP Ann - Manuf Technol. 2010;59(2):717–39.
11. Dimla D. Sensor signals for tool-wear monitoring in metal cutting operations—a review of methods. Int J Mach Tools Manuf [Internet]. 2000;40(8):1073–98. Available from: http://linkinghub.elsevier.com/retrieve/pii/S0890695599001224
12. Abellan-Nebot JV, Romero Subirón F. A review of machining monitoring systems based on artificial intelligence process models. Int J Adv Manuf Technol. 2010;47(1–4):237–57.
13. Sundara Murthy K, Rajendran I. Design and development of strain gauge based milling tool dynamometer. Int J Mach Mach Mater. 2010;7(3–4):286–98.
14. Rehorn AG, Jiang J, Orban PE, Bordatchev E V. Erratum: State-of-the-art methods and results in tool condition monitoring: A review (International Journal of Advanced Manufacturing Technology (2004)DOI: 10.1007/s00170-003-2038-2). Int J Adv Manuf Technol. 2005;26(7–8):942.
15. Audy J. Appraisal of techniques and equipment for cutting force measurement. J Zhejiang Univ Sci. 2006;7(11):1781–9.
16. Li X. Development of current sensor for cutting force measurement in turning. IEEE Trans Instrum Meas. 2005;54(1):289–96.
17. Ateş E, Aztekin K. Design, manufacturing, and calibration process of one piece lathe dynamometer for measurement in two axes. J Manuf Sci Eng. 2013;135(4):1–6.
18. Panzera TH, Souza PR, Rubio JCC, Abrão AM, Mansur TR. Development of a three-component dynamometer to measure turning force. Int J Adv Manuf Technol. 2012;62(9–12):913–22.
19. Yaldiz S, Ünsaçar F. Design, development and testing of a turning dynamometer for cutting force measurement. Mater Des. 2006;27(10):839–46.
20. Totis G, Sortino M. Development of a modular dynamometer for triaxial cutting force measurement in turning. Int J Mach Tools Manuf [Internet]. 2011;51(1):34–42. Available from: http://dx.doi.org/10.1016/j.ijmachtools.2010.10.001
21. Wang C, Rakowski R, Cheng K. Design and analysis of a piezoelectric film embedded smart cutting tool. Proc Inst Mech Eng Part B J Eng Manuf. 2013;227(2):254–60.
22. Yaldiz S, Ünsaçar F. A dynamometer design for measurement the cutting forces on turning. Meas J Int Meas Confed. 2006;39(1):80–9.
23. Karabay S. Design criteria for electro-mechanical transducers and arrangement for measurement of strains due to metal cutting forces acting on dynamometers. Mater Des. 2007;28(2):496–506.
24. O’Dogherty MJ. The design of octagonal ring dynamometers. J Agric Eng Res. 1996;63(1):9–18.
25. Patel VK, Patel MN. Development of Smart Sensing Unit for Vibration Measurement by Embedding Accelerometer with the Arduino Microcontroller. Int J Instrum Sci [Internet]. 2017;2017(1):1–7. Available from: http://journal.sapub.org/instrument
26. Rice WB, Salmon R. Effects of Cooling and Heating Workpiece and. 1966;6(c):143–52.
27. Pervaiz S, Deiab I, Ibrahim EM, Rashid A, Nicolescua M. A coupled FE and CFD approach to predict the cutting tool temperature profile in machining. Procedia CIRP [Internet]. 2014;17:750–4. Available from: http://dx.doi.org/10.1016/j.procir.2014.01.104
28. Minton T, Ghani S, Sammler F, Bateman R, Fürstmann P, Roeder M. Temperature of internally-cooled diamond-coated tools for dry-cutting titanium. Int J Mach Tools Manuf [Internet]. 2013;75:27–35. Available from: http://dx.doi.org/10.1016/j.ijmachtools.2013.08.006
29. Ostasevicius V, Markevicius V, Jurenas V, Zilys M, Cepenas M, Kizauskiene L, et al. Cutting tool vibration energy harvesting for wireless sensors applications. Sensors Actuators, A Phys [Internet]. 2015;233:310–8. Available from: http://dx.doi.org/10.1016/j.sna.2015.07.014
30. Haider J, Hashmi MSJ. Health and Environmental Impacts in Metal Machining Processes [Internet]. Vol. 8, Comprehensive Materials Processing. Elsevier; 2014. 7–33 p. Available from: http://dx.doi.org/10.1016/B978-0-08-096532-1.00804-9
31. von Turkovich BF, Durham DR. Machining of Titanium and Its Alloys. 1982;257–274.
32. Taylor CM, Giovana S, Hernandez A, et al. ScienceDirect ScienceDirect ScienceDirect Cutting fluid application for titanium alloys Ti-6Al-4V and Cutting fluid application for titanium alloys and Ti-10V-2Fe-3Al in a finish turning process Ti-10V-2Fe-3Al in a finish turning process new methodology t. Procedia CIRP [Internet]. 2018;77:441–444. Available from: https://doi.org/10.1016/j.procir.2018.08.279.
33. Namb M, Paulo D. Influence of Coolant in Machinability of Titanium Alloy (Ti-6Al-4V). J Surf Eng Mater Adv Technol. 2011;01:9–14.

Vibrations are a common problem in CNC turning operations, affecting the machine tool's overall performance and productivity. The geometrical accuracy and surface quality are reduced as a result of repeated vibrations, reducing tool life. Vibrations can now be sensed and responded, thanks to new advancements in electronic technology. The goal of this research work is to use a 3D accelerometer(sensor) to measure vibrations and determine the value of vibration and its causes by analyzing data on specific axes to take corrective action. Collecting vibration data while doing turning operation was needed to understand the impact of vibrations on Tool life & surface roughness. To capture vibration on the tool holder while turning, a 3D accelerometer (sensor) was attached or mounted on tool holder. The sensor attached to tool holder is connected to Arduino UNO, Arduino is connected to laptop. With the help of software and the Programme we can get the live reading of vibration while doing turning operation. Thus, real-time data on vibrations while turning will be available for analysis, with the use of electronic technology. After determining the vibration data the causes of vibrations, will be known to us. Then by variation in machining process parameters and reducing the causes of vibrations, we can improve the tool performance and quality of machining.

Keywords: CNC Turning, Vibrations, Surface quality, 3D Accelerometers, Machining parameters, Sensors.

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.

1. Zhao Y, Zhao Y, Liang S, Zhou G. A high performance sensor for triaxial cutting force measurement in turning. Sensors (Switzerland). 2015 Apr 3;15(4):7969–84.
2. American Society of Mechanical Engineers, IEEE International Conference on Service-Oriented Computing and Applications, IEEE International Conference on Advanced Intelligent Mechatronics (Busan) ; 2015.07.07-11.
3. Qehaja N, Jakupi K, Bunjaku A, Bruçi M, Osmani H. Effect of machining parameters and machining time on surface roughness in dry turning process. Procedia Eng. 2015;100(January):135–40.
4. Patil AS, Sunnapwar VK, Bhole KS, More YS. Experimental investigation and fuzzy TOPSIS optimisation of Ti6Al4V finish milling. Adv Mater Process Technol [Internet]. 2021;00(00):1–24. Available from: https://doi.org/10.1080/2374068X.2021.1971002
5. Tlusty J, Andrews GC. A Critical Review of Sensors for Unmanned Machining. CIRP Ann - Manuf Technol. 1983;32(2):563–72.
6. Yaldiz S, Ünsaçar F, Saǧlam H, Işik H. Design, development and testing of a four-component milling dynamometer for the measurement of cutting force and torque. Mech Syst Signal Process. 2007;21(3):1499–511.
7. Ramachandran KA/ L. DESIGN AND DEVELOPMENT OF SMART CUTTING TOOL. Available from: http://www.researchgate.net/publication/284936318
8. Miroslav RĆ, Predrag DĆ, Predrag JĆ. Experimental Determination of Cutting Force By Longitudinal Turning of C60E Steel. 2006;2(August 2017):113–9.
9. Hasibuzzaman M, Shufian A, Shefa RK, Raihan R, Ghosh J, Sarker A. Vibration Measurement Analysis Using Arduino Based Accelerometer. 2020 IEEE Reg 10 Symp TENSYMP 2020. 2020;(June):508–12.
10. Teti R, Jemielniak K, O’Donnell G, Dornfeld D. Advanced monitoring of machining operations. CIRP Ann - Manuf Technol. 2010;59(2):717–39.
11. Dimla D. Sensor signals for tool-wear monitoring in metal cutting operations—a review of methods. Int J Mach Tools Manuf [Internet]. 2000;40(8):1073–98. Available from: http://linkinghub.elsevier.com/retrieve/pii/S0890695599001224
12. Abellan-Nebot JV, Romero Subirón F. A review of machining monitoring systems based on artificial intelligence process models. Int J Adv Manuf Technol. 2010;47(1–4):237–57.
13. Sundara Murthy K, Rajendran I. Design and development of strain gauge based milling tool dynamometer. Int J Mach Mach Mater. 2010;7(3–4):286–98.
14. Rehorn AG, Jiang J, Orban PE, Bordatchev E V. Erratum: State-of-the-art methods and results in tool condition monitoring: A review (International Journal of Advanced Manufacturing Technology (2004)DOI: 10.1007/s00170-003-2038-2). Int J Adv Manuf Technol. 2005;26(7–8):942.
15. Audy J. Appraisal of techniques and equipment for cutting force measurement. J Zhejiang Univ Sci. 2006;7(11):1781–9.
16. Li X. Development of current sensor for cutting force measurement in turning. IEEE Trans Instrum Meas. 2005;54(1):289–96.
17. Ateş E, Aztekin K. Design, manufacturing, and calibration process of one piece lathe dynamometer for measurement in two axes. J Manuf Sci Eng. 2013;135(4):1–6.
18. Panzera TH, Souza PR, Rubio JCC, Abrão AM, Mansur TR. Development of a three-component dynamometer to measure turning force. Int J Adv Manuf Technol. 2012;62(9–12):913–22.
19. Yaldiz S, Ünsaçar F. Design, development and testing of a turning dynamometer for cutting force measurement. Mater Des. 2006;27(10):839–46.
20. Totis G, Sortino M. Development of a modular dynamometer for triaxial cutting force measurement in turning. Int J Mach Tools Manuf [Internet]. 2011;51(1):34–42. Available from: http://dx.doi.org/10.1016/j.ijmachtools.2010.10.001
21. Wang C, Rakowski R, Cheng K. Design and analysis of a piezoelectric film embedded smart cutting tool. Proc Inst Mech Eng Part B J Eng Manuf. 2013;227(2):254–60.
22. Yaldiz S, Ünsaçar F. A dynamometer design for measurement the cutting forces on turning. Meas J Int Meas Confed. 2006;39(1):80–9.
23. Karabay S. Design criteria for electro-mechanical transducers and arrangement for measurement of strains due to metal cutting forces acting on dynamometers. Mater Des. 2007;28(2):496–506.
24. O’Dogherty MJ. The design of octagonal ring dynamometers. J Agric Eng Res. 1996;63(1):9–18.
25. Patel VK, Patel MN. Development of Smart Sensing Unit for Vibration Measurement by Embedding Accelerometer with the Arduino Microcontroller. Int J Instrum Sci [Internet]. 2017;2017(1):1–7. Available from: http://journal.sapub.org/instrument
26. Rice WB, Salmon R. Effects of Cooling and Heating Workpiece and. 1966;6(c):143–52.
27. Pervaiz S, Deiab I, Ibrahim EM, Rashid A, Nicolescua M. A coupled FE and CFD approach to predict the cutting tool temperature profile in machining. Procedia CIRP [Internet]. 2014;17:750–4. Available from: http://dx.doi.org/10.1016/j.procir.2014.01.104
28. Minton T, Ghani S, Sammler F, Bateman R, Fürstmann P, Roeder M. Temperature of internally-cooled diamond-coated tools for dry-cutting titanium. Int J Mach Tools Manuf [Internet]. 2013;75:27–35. Available from: http://dx.doi.org/10.1016/j.ijmachtools.2013.08.006
29. Ostasevicius V, Markevicius V, Jurenas V, Zilys M, Cepenas M, Kizauskiene L, et al. Cutting tool vibration energy harvesting for wireless sensors applications. Sensors Actuators, A Phys [Internet]. 2015;233:310–8. Available from: http://dx.doi.org/10.1016/j.sna.2015.07.014
30. Haider J, Hashmi MSJ. Health and Environmental Impacts in Metal Machining Processes [Internet]. Vol. 8, Comprehensive Materials Processing. Elsevier; 2014. 7–33 p. Available from: http://dx.doi.org/10.1016/B978-0-08-096532-1.00804-9
31. von Turkovich BF, Durham DR. Machining of Titanium and Its Alloys. 1982;257–274.
32. Taylor CM, Giovana S, Hernandez A, et al. ScienceDirect ScienceDirect ScienceDirect Cutting fluid application for titanium alloys Ti-6Al-4V and Cutting fluid application for titanium alloys and Ti-10V-2Fe-3Al in a finish turning process Ti-10V-2Fe-3Al in a finish turning process new methodology t. Procedia CIRP [Internet]. 2018;77:441–444. Available from: https://doi.org/10.1016/j.procir.2018.08.279.
33. Namb M, Paulo D. Influence of Coolant in Machinability of Titanium Alloy (Ti-6Al-4V). J Surf Eng Mater Adv Technol. 2011;01:9–14.