The Importance of Vibration Study

Vibration is a mechanical phenomenon whereby oscillations occur about an equilibrium point. The
vibration mechanic could be demonstrated through the motion of a tuning fork, the reed in a woodwind
instrument or harmonica, a mobile phone, or the cone of a loudspeaker. In many cases, however,
vibration could contribute to waste energy and creating unwanted sound. For example, the vibrational
motions of engines, electric motors, or any mechanical device in operation are typically unwanted.
Such vibrations could be caused by imbalances in the rotating parts, uneven friction, or the meshing
of gear teeth. Careful designs usually minimize unwanted vibrations.
One of a device that makes use of vibration mechanic is milling machine. During machining
process, the chatter, also known as machining vibrations, corresponds to the relative
movement between the work piece and the cutting tool. The vibrations result in waves on the machined
surface. A chatter mark is an irregular surface flaw left by a wheel that is out of true in grinding or
regular mark left when turning a long piece on a lathe, due to machining vibrations. The use of high
speed machining (HSM) has enabled an increase in productivity and the realization of workpieces that
were impossible before, such as thin walled parts. Unfortunately, machine centers are less rigid because
of the very high dynamic movements. In many applications, such as long tools, thin workpieces, the
appearance of vibrations is the most limiting factor and compels machinist to reduce cutting speeds
well below the capacities of machines or tools.
In the scope of milling machine, vibrations is not always contributed positively to the overall
process of machining, it could also cause failure. For instance, misalignment just like unbalance, is a
major cause of machinery vibration. Some machines have been incorporated with self-aligning bearings
and flexible couplings that can take quite a bit of misalignment. This condition can be caused during
assembly or develop over time, due to thermal expansion, components shifting or improper reassembly
after maintenance. Next is the work piece, In Forced vibration case we assumed that the tool and
workpiece are rigid and vibrations are only originating from external oscillating source causing
resonance phenomenon whenever external vibration frequency coincides with natural frequency of
tool/workpiece. But in reality the cutting structure is not rigid and cutting force will cause deflections
as tool has mass and stiffness, and is prone to vibrate. Initial impact of tool with surface can set in
vibrations. This vibration during machining leaves a wavy surface behind and when next vibrating
tooth encounters this surface it changes the chip thickness. Therefore, the chip thickness at any instant
depends both on the tool deflection at that time and the workpiece surface left by previous tooth.
The easiest solution to overcome the problems arise is to use preventive maintenance on a regular
basis. The milling machine is equipped with oilers and grease fittings to ensure that the ways and other
contact areas are continuously lubricated. This would results in reduced or controlled vibration. To
lubricate the various places on the mill you will either use a grease pump. It is important to keep your
machine lubricated to avoid rust between the mating surfaces, and to avoid wear between surfaces.