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Controlling Vibration in Machining Operations

Vibration is common in machining and must be controlled to improve accuracy and productivity. There are three main types of vibration: free vibration caused by impulses, forced vibration excited by unbalanced masses or imperfections, and self-excited or chatter vibration resulting from a dynamic instability in the cutting process. Forced vibration can cause surface irregularities while chatter is more difficult to control and influences surface finish, accuracy, tool life, and machining rates. Chatter occurs due to variability in cutting forces and work hardening and can be destructive.

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406 views21 pages

Controlling Vibration in Machining Operations

Vibration is common in machining and must be controlled to improve accuracy and productivity. There are three main types of vibration: free vibration caused by impulses, forced vibration excited by unbalanced masses or imperfections, and self-excited or chatter vibration resulting from a dynamic instability in the cutting process. Forced vibration can cause surface irregularities while chatter is more difficult to control and influences surface finish, accuracy, tool life, and machining rates. Chatter occurs due to variability in cutting forces and work hardening and can be destructive.

Uploaded by

Leo Dev Wins
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We take content rights seriously. If you suspect this is your content, claim it here.
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  • Chatter: Introduces the concept of chatter in machining, setting the context for subsequent sections.
  • Vibration: Describes the role of vibration in machining operations and its impact on accuracy and productivity.
  • Types of Vibration: Outlines different vibration types: free, forced, and self-excited vibrations.
  • Free Vibration: Explains the characteristics of free vibrations and their decay over time.
  • Forced Vibration: Discusses the causes and consequences of forced vibrations in machine tools.
  • Self-Excited Vibrations: Focuses on self-excited vibrations, also known as machine tool chatter, and their causes.
  • Mechanism of Chatter: Describes the mechanisms behind chatter, including regenerative and mode coupling effects.
  • Effect of Chatter: Examines the detrimental effects of chatter on tools and machining processes.
  • Factors Affecting Chatter: Identifies factors contributing to chatter, such as machine rigidity and cutting speed.
  • Elimination of Chatter: Provides strategies for eliminating chatter through optimal parameter selection and damping techniques.

Vibration

Machining operations are invariably


accompanied by vibration.
To achieve higher accuracy and productivity
vibration in machine tool must be controlled.
Types of Vibration
Free vibration
Forced vibration
Self-excited vibration
Also called random or transient vibration
Caused by
- impulses transferred to the structure through its foundation,
- rapid reversals of reciprocating masses, such as machining
tables,
- the initial engagement of cutting tools.
Large force acts for a small time
The structure is deflected and oscillates in its natural
modes of vibration
These vibration decay rapidly with time due to the
Forced vibration
In machine tools, forced vibrations excited by
- unbalanced rotating masses (shaft, gears, toolholders and
tools),
- Bearing imperfection
- Misalignment in machine tool member
- pulsating oil pressure from gear pumps
- the intermittent engagement of multitooth cutters (milling),
- transmitted through the foundations from nearby machinery.
Forced vibration can produce
- waviness of the machined surface in finish grinding and
boring
- The shift of the machined surface (over- or undercut effect)
in slab milling,
- non-flatness of the machined surface in end milling with
helical cutters.
It can be reduced by
- Eliminating exciting force
- Changing the frequency of exciting force
- Increasing the machine tool stiffness
- Increasing damping
Self-excited vibrations
Results from
- a dynamic instability of the cutting process
- they develop due to the built-in (or intrinsic) mechanism
providing for a closed-loop relationship in the system.

This phenomenon is commonly referred as machine


tool chatter
Chatter
The causes and control of free and forced vibrations are
generally well understood and the sources of vibration can be
removed or avoided during operation of the machine.

Chatter vibrations are less easily controlled

- Chatter in metal cutting has a bad influence on surface finish and


dimensional accuracy of the workpiece,tool life and even machine life.

- metal removal rates are frequently limited because the operator must stop
the machine to improve the machining conditions, which often means
reducing the depth of cut or feed rate.
Self-excited vibrations (chatter)
induced and maintained by forces generated by the cutting
process.
- Variability of friction force between the chip and tool and between
the tool and work
- Non uniform work hardening of the layer being cut across its
thickness
- Instability of the build up edge which leads to changes in the cutting
angle and the cross sectional area of the uncut chip in the cutting
process
When it occurs in machining, it is inevitably violent, destructive
and difficult to eliminate

Vibration Machining operations are invariably accompanied by vibration. To achieve higher accuracy and productivity vibra
Types of Vibration Free vibration Forced vibration Self-excited vibration
Also called random or transient vibration Caused by - impulses transferred to the structure through its foundation, - rapi
Forced vibration In machine tools, forced vibrations excited by - unbalanced rotating masses (shaft, gears, tool holders an
Forced vibration can produce - waviness of the machined surface in finish grinding and boring - The shift of the machined
It can be reduced by - Eliminating exciting force - Changing the frequency of exciting force - Increasing the machine tool
Self-excited vibrations Results from - a dynamic instability of the cutting process - they develop due to the built-in (or
Chatter The causes and control of free and forced vibrations are generally well understood and the sources of vibration can
Self-excited vibrations (chatter) induced and maintained by forces generated by the cutting process. - Variability of fric

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