CHATTERING IN MACHINE TOOL

By,
A.N.Amudhan
One of the key questions in the operation of machine
tools is the vibrostability of the 'machine tool
machining' system, which to a great extent depends
on self-excited vibrations
The cutting of metals is frequently accompanied by
violent vibration of workpiece and cutting tool which
is known as machine-tool chatter.
Causes of vibration
vibrations are due to one or more of the following causes:
inhomogeneities in the workpiece material;
variation of chipcross section;
disturbances in the workpiece or tool drives;
dynamic loads generated by acceleration/deceleration
of massive moving components;
vibration transmitted from the environment;
self-excited vibration generated by the cutting process
or by friction (machine-tool chatter)

Machine-tool chatter is essentially a problem of
dynamic stability. A machine tool under vibration-free
cutting conditions may be regarded as a dynamical
system in steady-state motion. Systems of this kind
may become dynamically unstable and break into
oscillation around the steady motion

MACHINE-TOOL CHATTER
Chatter is a self-excited vibration which is induced and
maintained by forces generated by the cutting process.
It effects
surface finish,
diminish tool life
production rate and also
life of the bearings, spindle, motors, servos and other
machine components
produce noise
Chatter resistance of a machine tool is usually
characterized by a maximum stable (i.e., not causing
chatter vibration) depth of cut.

Tendency for chatter during machining is
proportional to the cutting forces and the depth and
width of the cut
Cutting forces increase with strength and the
tendency to chatter increases as hardness
increases
Continuous chips involve steady cutting forces and
do not cause chatter
Discontinuous chips and serrated chips cause
chatter

Factors Influencing Chatter
Guidelines for Reducing Vibration
and Chatter

1. Minimize tool overhang
2. Improve the stiffness of work-holding devices
and support workpieces
3. Modify tool and cutter geometry to minimize
forces or make them uniform
4. Change process parameters
5. Increase stiffness of the machine tool and its
components
6. Improve the damping capacity of the machine
tool

There are two types of stiffness to be considered when
looking at machine tools:
Static stiffness
Dynamic stiffness

Static, or structural, stiffness is determined by the
way the machine tool is built. The units of static
stiffness are measured in pounds per inch (lbs/in).
This indicates how many pounds of force it takes to
move a given amount along an axis.
If the deflection of the machine is causing chatter or
quality problems there are two options: the
machining parameters can be adjusted to reduce the
force of the cut or a different process or machine can
be used.
In general, the higher the static stiffness in a
machine, the more expensive that machine is going
to be.

Dynamic stiffness
Machining at or near the resonance frequency of a
machine will cause vibration.
The cutting tool tooth passing frequency, when
matched to the natural frequency of the system, will
drive the force out away from the material being cut
and a physical separation between the tool and the
material takes place creating chatter.