Anti-vibration Engineering in Internal Turning Using a Carbon Nanocomposite Damping Coating Produced by PECVD Process

Machining dynamic stability has been enhanced through a damping coating based on a novel carbon-based nanocomposite material. The coating was synthesized using a plasma enhanced chemical vapor deposition method, and deposited on to the round-shank boring bar used for internal turning and tested during machining. Comparisons between an uncoated and a coated boring bar were carried out at 0.25 mm and 0.5 mm depth of cut using a five times length to diameter ratio overhang, which are typical conditions known to generate detrimental mechanical vibrations. From sound pressure measurement it was found that the measured absolute sound level during process could be reduced by about 90% when using the tool coated with damping layer. Surface roughness measurements of the processed workpiece showed decreased Ra values from approximately 3-6 μm to less than 2 μm (and in 50% of the cases <1 μm) when comparing an uncoated standard tool with its coated counterpart. Moreover, it was found that the addition of an anti-vibration coating did not adversely affect other tool properties, such as rigidity and modularity.