International Journal of Machine Tools & Manufacture 51 (2011) 363–376

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International Journal of Machine Tools & Manufacture

journal homepage: www.elsevier.com/locate/ijmactool

Chatter in machining processes: A review

Guillem Quintana a, Joaquim Ciurana b,n
a
ASCAMM Technology Centre, Av Universitat Autónoma, 23, 08290 Cerdanyola del Valle s, Barcelona, Spain
b
Department of Mechanical Engineering and Civil Construction, Universitat de Girona, Av. Lluis Santaló s/n, 17071 Girona, Spain

a r t i c l e i n f o abstract

Article history: Chatter is a self-excited vibration that can occur during machining operations and become a common
Received 20 October 2010 limitation to productivity and part quality. For this reason, it has been a topic of industrial and
Received in revised form academic interest in the manufacturing sector for many years. A great deal of research has been carried
5 January 2011
out since the late 1950s to solve the chatter problem. Researchers have studied how to detect, identify,
Accepted 6 January 2011
avoid, prevent, reduce, control, or suppress chatter.
Available online 15 January 2011
This paper reviews the state of research on the chatter problem and classifies the existing methods
Keywords: developed to ensure stable cutting into those that use the lobbing effect, out-of-process or in-process,
Chatter and those that, passively or actively, modify the system behaviour.
Vibration
& 2011 Elsevier Ltd. All rights reserved.
Stability
Machining
Review

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
1.1. Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
1.2. Chatter relevance in machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
1.3. Self-excitation mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
1.4. Stability lobe diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
2. Strategies for ensuring stable machining processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3. Out-of-process strategies for stability lobe diagram identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4. In-process strategies for chatter recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
5. Passive chatter avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
6. Active chatter elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
7. Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

1. Introduction Every year it is possible to observe in fairs, conferences and of

course, in the market, how production capabilities have increased
1.1. Generalities thanks to the development of new concepts, devices, materials,
tools, coatings, structures, etc. Accuracy, flexibility and produc-
Technologies involved in machining operations have advanced tivity are enhanced constantly with innovative solutions to
greatly in the recent decades and machines have experienced achieve market demands or even raise them to higher levels. In
significant changes such as the incorporation of numerical control. the end, all these improvements are possible thanks to the
generation of knowledge. Understanding metal cutting funda-
mentals has become a key factor in recent decades but this is not
an easy task due to complexities of the chip formation mechan-
n
Corresponding author. Tel.: +34 972 418265; fax: + 34 972 418098.
ism. Recent trends, thanks to advances in computers and sensors,
E-mail addresses: gquintana@ascamm.com (G. Quintana), seem to be focused on the online monitoring, measuring and
quim.ciurana@udg.edu (J. Ciurana). control of the machining process. Several kinds of sensors and

0890-6955/$ - see front matter & 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2011.01.001
364 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
signal processing techniques have been developed for the direct
or indirect diagnosis of aspects such as the workpiece condition
(surface roughness, integrity, and dimensional accuracy), the
detection of tool wear and breakage, the identification of chatter,
the analysis of machine component conditions, etc. The develop-
ment of science, technology and technique, and the pressure of
competitive markets have stimulated the expansion of manufac-
turing frontiers. Despite of all these advances, however, chatter
vibration has been, for the last sixty years, a limitation to
improving productivity and part quality in metal removal pro-
cesses. This phenomenon has been a popular topic for academic
and industrial research.
Metal cutting processes can entail three different types of
mechanical vibrations that arise due to the lack of dynamic
stiffness of one or several elements of the system composed by
the machine tool, the tool holder, the cutting tool and the
workpiece material. These three types of vibrations are known
as free vibrations, forced vibrations and self-excited vibrations [1].
Free vibrations occur when the mechanical system is displaced
from its equilibrium and is allowed to vibrate freely. In a metal
removal operation, free vibrations appear, for example, as a result
of an incorrect tool path definition that leads to a collision
between the cutting tool and the workpiece. Forced vibrations
appear due to external harmonic excitations. The principal source
of forced vibrations in milling processes is when the cutting edge
enters and exits the workpiece. However, forced vibrations are
also associated, for example, with unbalanced bearings or cutting
tools, or it can be transmitted by other machine tools through the
workshop floor. Free and forced vibrations can be avoided,
reduced or eliminated when the cause of the vibration is identi-
fied. Engineers have developed several widely known methods to
mitigate and reduce their occurrence. Self-excited vibrations
extract energy to start and grow from the interaction between
the cutting tool and the workpiece during the machining process.
This type of vibration brings the system to instability and is the
most undesirable and the least controllable. For this reason,
chatter has been a popular topic for academic and industrial
research.
The first investigations of machine tool vibrations and instabil-
ities appeared at the beginning of the 20th century as the result of
metal removal process improvement. In the 20th century
machine tools experienced a considerable evolution and became
more powerful, precise, rigid and automatic. This growth was
stimulated by general industry development, especially in the
case of aerospace, mould and automotive industries with, for
instance, the mass production of the Ford Model T [2]. But with all
these improvements in the manufacturing sector, new limitations
and challenges also appeared. Machines and structures are not
rigid bodies, but rather systems consisting of elastic components
that respond to external or internal forces with finite deforma-
tions. In addition, there are relative motions between the compo-
nents, giving rise to internal forces. Due to these internal and
external forces, the machine or structure moves. This motion, as a
result of internal and external forces, is the subject of dynamics
and vibration [3]. In 1907, Taylor [4] stated that chatter is the
‘‘most obscure and delicate of all problems facing the machinist’’.
Many years later, in May 1961, Tobias [1] exposed in the preface
of his book Schwingungen an Werkzeugmaschinen: ‘‘Machine
tool development in recent decades has created an increasing
number of vibration problems. Machine tool designers in early
development phases are worried about vibration characteristics;
production engineers know that vibrations diminish tool life,
generate unacceptable surface finishes on the parts and reduce
productivity’’. Nowadays, authors still refer to vibrations as a
limiting factor, one of the most important machining challenges
and, of course, an aspect to be improved.
1.2. Chatter relevance in machining
Chatter has been and still is a very important topic in
manufacturing research. That persistent relevance over the years
can be explained by two principal factors: the complexity of the
phenomenon makes its study and understanding nontrivial; and
the negative effects of chatter stimulate interest in solving the
problem.
With regard to the first factor, chatter is a highly complex
phenomenon due to the diversity of elements that can compose
the dynamic system and its behaviour: the cutting tool, the tool
holder, the workpiece material, the machine tool structure and
the cutting parameters. Predicting its occurrence is still the
subject of much research, even though the regenerative effect,
the main cause of chatter, was identified and studied very early
on [5,6]. Moreover, chatter can occur in different metal removal
processes: milling [7–13], turning [14–27], drilling [28–33], bor-
ing [34–40], broaching [41,42] and grinding [43,44].
Regarding the second point, chatter occurrence has several
negative effects:
 Poor surface quality.
 Unacceptable inaccuracy.
 Excessive noise.
 Disproportionate tool wear.
 Machine tool damage.
 Reduced material removal rate (MRR).
 Increased costs in terms of production time.
 Waste of materials.
 Waste of energy.
 Environmental impact in terms of materials and energy.
 Costs of recycling, reprocessing or dumping non-valid final
parts to recycling points.
For these reasons, chatter avoidance is a topic of enormous
interest. In workshops, machine tool operators often select con-
servative cutting parameters to avoid chatter and, in some cases,
additional manual operations are required to clean chatter marks
left on the part surface. This common practise usually results in a
decrease in productivity. In the automotive industry, Renault
S.A.S. estimated the cost due to chatter on a cylinder block of a
Renault 2.0 l DCi to be around 0.35h per piece. As this company
produces around 3 million engines a year, chatter avoidance was
strategic [45]. And this interest has stimulated a great deal of
research. Fig. 1 shows the evolution of the number of publications
per year from 1966 to 2009. The word ‘‘chatter’’ was searched in
article titles, abstracts or keywords in a Scopuss [46] database,
considering all document types in the subject area of physical
sciences, published during that forty-three-year period and then
refining the search manually to define a more specific subject
area. The increase in research produced over the years, and
particularly during the last decade, is shown in graph.
A search of the SciVerse Hub platform [47] across SciVerse
ScienceDirect and SciVerse Scopus contents revealed that the
authors, who report most about the chatter problem today are
Altintas, Budak and Tlusty. Table 1 shows the 10 most prolific
authors.
1.3. Self-excitation mechanisms
Chatter is generally classified in two categories: primary and
secondary. Primary chatter can be caused by the cutting process
itself (i.e. by friction between the tool and the workpiece, by
thermo-mechanical effects on the chip formation or by mode
coupling). Secondary chatter may be caused by the regeneration
 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376 365

140

Number of publications on chatter

120

100

80

60

40

20

0
1966

1969

1971

1973

1975

1977
1979

1981

1983

1985

1987
1989

1991

1993

1995

1997
1999

2001

2003

2005

2007

2009
Year

Fig. 1. Chatter publications per year.

Table 1
Most prolific chatter problem authors.
1. Altintas, Y. 51 publications
2. Budak, E. 29 publications
3. Tlusty, J. 23 publications
4. Marui, E. 23 publications
5. Ismail, F. 21 publications
6. Insperger, T. 20 publications
7. Stepan, G. 18 publications
8. Schmitz, T.L. 18 publications
9. Tobias, S.A. 16 publications
10. Ota, H. 16 publications

of waviness of the workpiece surface. This regenerative effect is

the most important cause of chatter. For this reason it has become
a convention and been followed by a lot of the publications that
’’chatter’’ only refers to regenerative chatter. However, it has to be
mentioned that it is possible to distinguish between frictional
chatter, thermo-mechanical chatter and mode coupling chatter
and regenerative chatter depending on the self-excitation
mechanism that causes the vibration [48].

 Frictional chatter occurs when rubbing on the clearance face Fig. 2. Regeneration of waviness in a milling model with two degrees of freedom.
excites vibration in the direction of the cutting force Fc and Source: [56].
limits in the thrust force Ft direction [49].
dominant and build up chatter [55]. Fig. 3 shows the influence
 Thermo-mechanical chatter occurs due to the temperature and
of this phase difference on chip thickness [48]. If the relative
strain rate in the plastic deformation zone [50].
phase difference is zero, the dynamic chip thickness is also
 Mode coupling chatter exists if vibration in the thrust force
zero (Fig. 3a). If the relative phase is p, the dynamic chip
direction generates vibration in the cutting force direction and
thickness variation is maximum (Fig. 3c). Consequently, the
vice versa [1,51,52]. This results in simultaneous vibration in
force on the cutter depends, among other factors, on the
the cutting and thrust force directions. Physically, it is caused
displacement of the previous tooth.
by a number of sources such as friction on the rake and
clearance surfaces, chip thickness variation, shear angle oscil-
lations and regeneration effect [50]. 1.4. Stability lobe diagrams
 Regenerative chatter is the most common form of self-excited
vibration. It can occur often because most metal cutting The border between a stable cut (i.e. no chatter) and an
operations involve overlapping cuts which can be a source of unstable cut (i.e. with chatter) can be visualised in terms of the
vibration amplification. The cutter vibrations leave a wavy axial depth-of cut as a function of the spindle speed. This is a
surface (see Fig. 2). When milling the next tooth in cut attacks stability lobe diagram or SLD (see Fig. 4). These diagrams can be
this wavy surface and generates a new wavy surface. The chip used to find the specific combination of machining parameters
thickness and, hence, the force on the cutting tool vary due to that results in the maximum chatter-free material removal rate
the phase difference between the wave left by the previous [55]. The idea is to seek regions of stability within lobes as shown
teeth (in turning it is the surface left after the previous in Fig. 4, taking advantage of the lobbing effect and looking for the
revolution) and the wave left by the current ones [50,53,54]. best option depending on the criteria selected, such as time, cost,
This phenomenon can greatly amplify vibrations, become benefit and accuracy.
366 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
ε = 0 rad.
Fig. 3. Effect of phase of subsequent tooth passing on chip thickness.
Source: [48].
Unstable region
Lobbing effect
Axial depth of cut (mm)
Process damping
Stable region Chatter free operation
Spindle Speed (rpm)
Fig. 4. Stability lobe diagram.
At high speeds, the stabilizing effect of process damping
diminishes, making the process more prone to chatter. Process
damping usually occurs at low spindle speeds and provides the
stability due to the short undulations left on the part’s surface by
high-frequency vibrations. These surface waves interfere with the
cutting tool flank face and dampen the cutting tool vibration.
The construction of an SLD requires previous information
about, for example, the frequency response function, FRF, of the
cutting tool, tool holder, machine tool and workpiece material
combination. But modelling the process to identify the SLD is not
an easy task because the multi-degree-of-freedom structures, the
multiple cutting teeth, and the variable cutting forces and chip-
load directions complicate the analysis and the calculation. Thus,
once the frequency response function (FRF) of the machine tool
system has been identified, the SLD can be calculated for a
specified cutter, workpiece material and radial immersion, and
the workshop operator can select combinations of axial depth-of-
cut and spindle speed that ensure chatter-free operations.
2. Strategies for ensuring stable machining processes
Researchers generally talk about detecting, identifying, avoiding,
preventing, reducing, controlling, or suppressing chatter. A review of
the great deal of literature regarding the chatter problem leads to
a classification of the existing methods into two main groups.
The first group is composed of all those methods that ensure a
stable machining process by selecting cutting parameter combi-
nations in the stable zone of the SLD and making the most of the
lobbing effect. The second group includes those methods that
avoid chatter by changing the system behaviour and modifying
the stability frontier. Fig. 5 presents the main lines of research on
chatter vibrations.
Regarding the first group, it is possible to distinguish between out-
of-process and in-process methods. The out-of-process subcategory
includes those methods that aim to predict the location of the
ε = 1/2 π rad. ε = π rad.
stability boundary of the cutting process to select stable cutting
parameter combinations. The SLD identification is done out-of-
process before the beginning of the manufacturing process. The in-
process subcategory includes those methods that detect chatter
during the metal cutting process, allowing the parameters to be
corrected so that the cut migrates to stable zones. In the first case the
stability frontier must be calculated before the beginning of the
machining operation. In the second one, it is necessary to identify
chatter occurrence in-process, as soon as the phenomenon arises, to
modify the cutting parameters until a stable cut is achieved.
In the second group it is possible to distinguish between
passive and active methods. The first include strategies based
Chatter occurrence on modifying certain machine tool elements to passively change
the behaviour of the system composed of the machine tool, the
cutting tool and tool holder. The active methods are based on
certain elements capable of modulating the quantity of work
provided, absorbing or supplying energy with the aim of actively
raising or at least changing, the stability frontier.
In the following sections the proposed chatter research lines
are presented in more detail. However, in some cases, researchers
blend or combine different strategies into a single approach or
contribution. Therefore, classifying methods into one of the
above-described groups is not an easy task because certain
methods are not strictly followed but rather combined to develop
new approaches. Taking that into account, the four major cate-
gories considered are explained in the next sections.
3. Out-of-process strategies for stability lobe diagram
identification
This research line is focused on avoiding chatter phenomena
without modifying the characteristics of the system composed by
the machine tool structure, the tool holder and cutting tool. The aim
is to select optimal cutting parameters by seeking stable regions
between the lobes of the stability chart. At low spindle speeds the
stabilizing effect of the process damping is dominant and chatter does
not usually appear. At higher spindle speeds, the effect of process
damping diminishes and it is necessary to analyse the lobbing effect
in order to optimise the material removal process. To carry out this
strategy the complete SLD or, at least, the SLD in the working speed
range, must be identified. During the many years of chatter research,
investigators have proposed several models for chatter prediction in
different manufacturing processes. In [57], Altintas and Weck review
the fundamental modelling of chatter vibrations in turning, boring,
drilling, milling and grinding processes. Research production is more
prolific when using technologies, such as turning or milling, which
are more conventional, relevant and widely used in the industry. For
this reason there is much more literature on the chatter problem in
milling or turning than in other less common processes, such as
boring or broaching.
The first approaches were presented by Tobias and Fishwick
[5] and Tlusty and Polacek [51]. They identified the regeneration
mechanism and developed mathematical models in the form of
 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
Fig. 5. Research lines focussed on chatter vibration.
delay differential equations (DDEs). Merrit [58] present a feed-
back model of the system, explaining it as a closed-loop interac-
tion between the structural dynamics and the cutting process.
Minis et al. [7] present a general mathematical model that
described the milling dynamics to predict the limit of axial depth
of cut for chatter-free milling. The zeroth order approximation,
ZOA, method of Altintas and Budak [56] is an indispensable
reference. Presented in 1995 in the Annals of CIRP, this work
has become the most referenced paper dealing with the chatter
problem (more than 300 citations). The authors suggested making
stability predictions using the zeroth order Fourier term to
approximate the cutting force variation and achieve reasonably
accurate SLD predictions for processes, where the cutting force
varies relatively little, i.e. considerable radial immersions and
large number of teeth. This analytical method to predict stability
lobes was enhanced by Altintas [59] to a three dimensional
model. Other researchers have attempted to predict the SLD using
analytical methods. Insperger and Stépán [60,61] applied the
semi-discretization (SD) method to convert the DDE into a series
of autonomous ordinary differential equations (ODEs) with
known solutions. Henninger and Eberhard [62] propose methods
to increase the computational efficiency of the semi-discretiza-
tion method for the general case of interrupted and non-inter-
rupted processes and their corresponding DDEs, reducing the
method’s computational cost and increasing its accuracy.
Improvements are demonstrated in 2-DOF milling. Gradišek
et al. [63] compare the stability boundaries predicted by ZOA
and SD methods and conclude that the two methods obtain
similar predictions of SLD for high radial immersions but that,
for low radial immersions, the predictions present considerable
differences. Analytical investigations led to implementation of
bifurcation methods, i.e. Hopf bifurcation and period doubling or
Flip bifurcation, for stability prediction [64,65].
To identify the SLD, the system behaviour must be predicted or
modelled by characterizing or simulating the response of the
machine tool, tool holder and cutting tool system. The transfer
function of a multi-degree-of-freedom system can be identified
by structural dynamic tests. The structure is excited with an
impact hammer instrumented with a piezoelectric force transdu-
cer and the resulting vibrations are measured with displacement,
velocity or acceleration sensors [54]. Usually an impact hammer
is used. The impact force that the hammer provides has a short
duration and can be analysed as a narrow pulse with a flat
frequency spectrum. Thus it is excited a wide frequency range,
which contains the natural modes of the system. However,
367
electromagnetic or electrohydraulic shakers are more effective
in exciting the structure than the impact hammer as the can
provide force at random frequencies and amplitudes [54]. It is
important to select the hammer and the tip material considering
the mass and rigidity, of the structure. It is very common to use
accelerometers for measuring the resulting vibrations. It is also
important to select the adequate mass and frequency range of the
accelerometers. Also, the interface material between the structure
and the accelerometer must be carefully selected to be able to
perform accurate measurements. Non-contact sensors are useful
in order to avoid the effect of the accelerometer mass on the
measurement but it can be difficult to mount them on machine
tool. Laser displacement transducers are more practical to mount.
Fig. 6 shows a schematic representation of the impact hammer
testing procedure. Once the transfer function of the system is
identified, it is necessary to evaluate the cutting coefficients for
specified cutting conditions. Cutting coefficients can be obtained
from measurements of forces in feed and normal directions of
cutting. As instantaneous chip thickness and vibration depend on
cutting forces and modal parameters the problem leads to a
closed-loop representation. The identification of the eigenvalues
of the closed-loop dynamic system equation permits to obtain the
SLD defined as the maximum stable axial depth of cut as a
function of spindle speed. Once the transfer function of the
structure at the cutting point and the cutting constant are
identified or measured, the SLD can be calculated following
several steps: (1) Selecting a chatter frequency around a domi-
nant mode; (2) Calculate the phase angle of the structure at the
chatter frequency selected; (3) Calculate the critical depth of cut;
(4) Calculate the spindle speed for each stability lobe; and (5)
Repeat the procedure by scanning the chatter frequencies around
all the structure natural frequencies. [56]. Some commercial
solutions, such as the CutPros software package, simplify the
test and offer automatic predictions of the SLD [66]. Sims et al.
[67] describe the use of piezoelectric sensors and actuators to
predict milling SLDs. This approach offers more control over the
excitation signal than an impact hammer and is more suitable for
small tools, where it is impossible to accurately strike the tool tip.
Substructure coupling techniques allow the dynamics of the
spindle and the tool to be studied separately, then combined to
obtain the system’s global response. Consequently, once the
spindle dynamics have been studied theoretically or experimen-
tally, it is possible to estimate the response at the tool tip for
different tools [68,69]. Given the importance of both the tool
diameter and overhang on the dynamic behaviour, this technique
368 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
Accelerometers
Hammer
PC
FRF XX (Real part)
-4
x10
2 other process phenomena and specificities that would improve
1.5
1
mm/N
0.5
0 high rotating speeds, the gyroscopic effect on the spindle
-0.5
-1
100 200 300 400 500 600 700 800
Hz
FRF YY (Real part)
x10 -4
2 the cutting tool and the workpiece, but also considering the effect
1.5
1 ing increases stability in machining at low cutting speeds and is
mm/N
0.5
0 cients are difficult to identify. Budak and Tunc [77] present a
-0.5
-1
100 200 300 400 500 600 700 800
Hz
Fig. 6. Schematic representation of impact hammer testing.
is very useful for machine tool users. If spindle and machine
manufacturers integrate the dynamics of each of their products in
a software utility, the final user can introduce the specific
geometry of the tools to obtain the frequency response. This FRF
is input for the stability lobe calculation, which leads to the
selection of highly productive conditions. At 0 rpm, excitation and
response measurement is the method typically used to obtain the
FRF and can be easily made by tap testing the tool tip with an
impact hammer and an accelerometer. However, at higher speeds
tap testing is not possible. Therefore, alternative procedures have
been proposed for both non-contact excitation and response
measurement. Abele et al. [70,71] used an active magnetic
bearing (AMB) to identify the spindle tool system’s FRF. This
method allows a non-contact measurement to be made while the
spindle is running. Moreover, impact tests involving acceler-
ometers are commonly used in FRF measurements and although
the mass of a typical accelerometer used in these measurements
is extremely small compared with the cutting tool, it can have a
significant effect on the FRF measurement. Özs- ahin et al. [72]
demonstrate the effect of the accelerometer’s mass on tool point
FRFs and stability diagrams for several cases with different tool-
to-accelerometer mass ratios using laser velocity measurements.
The authors also present a structural modification method that
can be used to correct the FRFs measured with accelerometers,
and thus the resulting stability diagrams. Methods used nowa-
days for FRF identification require the use of additional equip-
ment such as impact hammers, piezoelectric transducers,
software, sensors and qualified staff to perform tests, validate
data and interpret frequency response functions. In most of cases,
workshops are not able to acquire this additional equipment and,
even if they could, operators would not be able to use these
complex SLD generation systems. This could be the reason they
are still not widely used in small and medium-sized workshops.
Nevertheless, this line, principally focused on modelling the
cutting process and understanding the chip formation and chatter
occurrence mechanisms, is the most powerful line when it comes
to generating knowledge about the metal removal process and
the phenomena taking place in the cutting zone.
However, some aspects in milling are still difficult to model,
for instance, the spindle dynamic behaviour variation at high
rotational speeds, where the centrifugal force on the bearings, the
gyroscopic effect and thermal effects change the performance of
the spindle. Over the years, researchers have added more factors
to the models, increasing their complexity but also, considering
their accuracy. Movahhedy and Mosaddegh [73] included the
gyroscopic effects of the rotating spindle to obtain the FRF. At
dynamics becomes more relevant, affecting the stability borders
of the system. Zatarain et al. [74] analyse the influence of mill
helix angle on stability. Insperger et al. [75] took into considera-
tion the role of the tool run-out on process stability. Vela-
Martı́nez et al. [76] present a multi-degree-of-freedom model
for chatter prediction in turning, based on compliance between
of the dynamic characteristics of the cutting tool. Process damp-
usually ignored in chatter analyses as process damping coeffi-
practical identification and modelling method, where process
damping coefficients are obtained from chatter tests. Filiz et al.
[78] present a tool-holder model that incorporates a spectral-
Chebyshev technique with the Timoshenko beam equation to
obtain a completely parameterized solution to effectively model
the tool-tip dynamics for arbitrary tool-holder combinations
using the receptance coupling substructure analysis (RCSA) tech-
nique. Tang and Liu [79] study the effect of helix angle and
normal rake angle on stability in end milling under the same
milling parameters, and plot three-dimensional stability lobes to
show that milling stability is increased with the increment of
helix angle and normal rake angle. Zatarain et al. [80] analyse the
concept of directional factors for chatter stability in milling,
focusing on the importance of multi-frequency calculation and
including the effect of the helix angle to select the best cutting
conditions. Shamoto and Akazawa [81] focus on ball-end milling
processes. The authors developed an analytical method to predict
chatter stability that considers the tool inclination to compute the
directional milling force coefficients. Ahmadi and Ismail [12]
present a dynamic model to study chatter in the flank milling of
curved surfaces on a five-axis machine. The authors calculated
feed rate by post-processing the tool path and perform chatter
simulation in the time domain. Henninger and Eberhard [82]
propose modelling techniques that compute stability diagrams for
milling processes with parallel kinematic machine tools. Garitao-
nandia et al. [83] presents a method to solve the roots of the
characteristic equation of the centreless grinding process based
on the root locus method. Sajjadi and Movahhedy [84] focus on
reaming processes. The authors used a time domain approach to
simulate the cutting conditions in reaming processes that lead the
system to regenerative chatter vibrations. The dynamic analysis
of the proposed system includes inertia of the tool, centripetal
and Coriolis terms, damping and the first mode bending of the
reamer. Beside analytical models, other techniques have been
used to identify the SLD of the system. Modelling approaches are
 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
usually very sophisticated and operators are not trained well
enough to apply them, interpret them and make decisions. The
modelling itself includes some simplifications that entail errors or
inaccuracies, which make the predictions differ from the reality.
Stability lobes are very sensitive to the model’s input parameters:
modal parameters and the cutting coefficients that quantify the
resistance of the material to being cut. An error in the estimation
of the stiffness or the damping coefficient increases the limiting
depth of cut in approximately the same proportion. An error in
the cutting coefficients lowers the depths in the same proportion.
Hence, in spindle-tool chatter, the SLD obtained is only valid for
one combination of these elements: machine tool, spindle, tool
holder and tool with a given overhang. Changes in the shape or
the mechanical properties of the tool or the tool holder require
new stability lobes. In the same way, the same tool and tool
holder do not have the same performance on different spindles.
As an alternative to modelling approaches, other methods
based on experimental, probabilistic or artificial intelligence
approaches have been proposed to calculate real stability lobe
diagrams. Approaches based on experiments do not present
inaccuracies due to the consideration of simplifications and do
not require extra know-how. However, they are limited to one
specific system: machine tool, spindle, tool holder, tool, material.
Quintana et al. [85] propose an experimental method for identify-
ing SLDs in milling operations based on empirical tests where the
workpiece, thanks to its inclined plane shape, permits a gradual
increase of the axial depth of cut in the feed direction, which
represents the y coordinate of the SLD, while the spindle speed
(the x coordinate of the SLD) is increased between passes. The
cutting process is interrupted as soon as chatter is detected and
the frontier between stable and unstable cutting, i.e. the stability
lobe diagram, is physically machined onto the workpiece. In
another experimental approach, Quintana et al. [86] propose the
sound mapping technique for SLD identification in milling pro-
cesses. Later on, Quintana et al. [87] propose a predictive experi-
mental method to identify real stability lobe diagrams using the
inclined plane experimental procedure and simplifying the num-
ber of experiments for the complete SLD prediction. Totis [88]
proposes a probabilistic algorithm, the robust chatter prediction
method (RCPM), for chatter prediction in milling. The method is
based on the analysis of an uncertain dynamic milling model,
which is defined as the family of deterministic models obtained
by varying model parameters within their confidence intervals.
Stable regions are identified by applying a new stability criterion
based on level curves and the gradient of the probabilistic lobes
obtained. Kotaiah et al. [89] propose a neural network-based
optimisation scheme for predicting localised stable cutting states
in inward turning operations, where cutting parameters are
predicted using binary-coded genetic algorithms. Khachan and
Ismail [90] developed a graphical approach for time-domain
simulation of chatter in multi-axis milling. The graphical chatter
simulation approach shows agreement with the traditional
numerical simulation method. However, there are limitations of
the graphical method due to the pixel size in relation to the
vibration amplitude and frequency.
Some researchers have used finite element analysis (FEA) or
the finite element method (FEM) for stability simulation and
prediction [46,91–95]. With this method it is possible to predict
the machine tool behaviour or the behaviour of some components
in the design stage, before they are constructed, with the
advantages that entails. Mahnama and Movahhedy [96] present
an approach for the prediction of machining chatter based on FEM
simulation of chip formation under dynamic conditions. Garitao-
nandia et al. [97] propose a dynamic model of a centreless
grinding machine based on FEM. Biermann et al. [98] developed
a finite element (FE) model for the workpiece coupled with
369
geometric milling simulation to compute regenerative workpiece
vibrations in five-axis milling of turbine blades. Seguy et al. [99]
also propose the use of the FEM to calculate 3D stability lobes for
the milling of thin walls and thin floors. That chatter is almost
unavoidable, especially in those cases, where long slender end
mills or highly flexible thin-wall parts, such as air-frame or
turbine engine components, are involved [50]. The FEM permits
estimation of the dynamic stiffness to calculate stability lobes
under working conditions prior to spindle manufacturing. Thus,
spindle models make it possible to observe the effect of every
change in design on the spindle performance, saving time
and money.
Workpiece vibrations in thin-walled parts have an important
influence on the process and the quality of the resulting surface.
Their machining can become a critically difficult problem due to
the variable dynamics of the parts, and has become a topic of
special interest and research. Gonzalo et al. [100] focus their work
on the simulation of thin-walled part machining in aluminium.
Campa et al. [101,102] solved the problem of the variable
dynamics of a thin-walled part through the calculation of 3D
stability lobes, where the third dimension is the tool position
along the part. Song et al. [103] describe a method for predicting
the stability of thin-walled workpiece milling taking into account
that the dynamic characteristics of the workpiece vary with tool
positions. Tang and Liu [104] studied the machining stability in
milling of the thin-walled parts and develop a three-dimensional
lobe diagram of the spindle speed, axial, and radial depth of cut to
choose the appropriate cutting parameters according to the
dynamic behaviour of the chatter system and find the maximum
material removal rate through optimal pairs of the axial and
radial depths of cut.
More recently micro-machining has emerged as a new topic of
interest. In this process, miniature cutting tools at high rotational
speeds modify the cutting phenomena, the dynamics and the
cutting coefficients of the operation and affect the stability lobes
[105]. In micro-machining the tool tip dynamics and cutting
coefficients are required to predict chatter stability, but measure-
ment of the tool tip dynamics is not possible through direct
impact hammer testing due to the small tool shape. Rahnama
et al. [106] propose the use of the equivalent volume interface
between the tool and the workpiece to determine the process
damping parameter and obtain the dynamics at the tool tip
indirectly with the receptance coupling method, and the mechan-
istic cutting coefficients are obtained from experimental cutting
tests. Biermann and Baschin [107] analyse the influence of cutting
edge geometry, the cutting edge radius and the feed per tooth on
the tool vibration trajectories and the stability of micro-milling
processes. The authors present the results of experimental
research with microend-milling cutters (d ¼1 mm). Novakov and
Jackson [108,109] present an overview of chatter vibration and
chatter suppression in drilling and micro-machining.
4. In-process strategies for chatter recognition
The estimation of lobes explained above is the off-line
approach to prevent unstable machining through stability frontier
identification. If the lobes are carefully calculated, the operator
can optimise cutting conditions for stable machining by seeking
regions between lobes. This permits a large axial depth of cut to
be machined and increases the material removal rate. However,
this approach implies a complete analysis of machine dynamics,
which is difficult for industrial users to carry out, and requires in-
depth knowledge of the machining process and material [110].
Moreover, in some cases (e.g. where there are more than three
axes or for thin-walled workpieces), the SLD of the system cutting
370 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
tool, machine tool and workpiece is continuously changing and it
is difficult to make predictions in advance and schedule the
correct parameters to ensure stable operations [111]. The meth-
ods based on chatter recognition do not need SLD identification.
For such cases, researchers have developed methods consisting of
online chatter detection, by monitoring a certain signal such as
vibration, sound, power, etc. (as shown in Fig. 7) with different
types of sensors or instruments to obtain process information.
Rahman and Ito [112] propose a method to determine the
onset of chatter through the in-process measurement of the
horizontal deflection of the workpiece. Liao and Young [113]
propose an online spindle speed regulation method to control
chatter when it starts to occur. The dynamic cutting force signal is
collected with a dynamometer, the fast Fourier transform is
calculated, and a new spindle speed is computed with the goal
of disturbing the regeneration mechanism.
The milling sound emerging from the mechanical vibrations
produced in the interaction zone between the cutting tool and the
workpiece has also been used to detect chatter and control its
occurrence [114–118]. It has been demonstrated that a micro-
phone is an excellent sensor to be used with this objective and
comparisons made with other sensors, such as dynamometers,
displacement probes and accelerometers, have given good results
regarding unstable milling identification [114]. Schmitz et al.
[115,116] and Schmitz [117] propose a method for chatter
recognition through statistical evaluations of the milling sound
variance with a synchronously sampled (one sample per spindle
TM
revolution) signal. A software programme called Harmonizer by
s
Metalmax [119] scans the sound of the cutting process with a
microphone and chatter is detected if the energy of the measured
sound signal exceeds a certain threshold. Ismail and Ziaei [120]
combined several strategies into one, focusing on the cutting of
flexible aluminium turbine blades on a five-axis machine. They
implemented an algorithm that combines off-line scheduling of
parameters and online spindle speed ramping based on process
sound analysis data. Tsai et al. [121,122] present real-time chatter
prevention carried out by feedback of an acoustic cutting signal
and propose a spindle speed compensation strategy. Recently,
Okuma [123] has presented a commercial solution for chatter
Microphone
Accelerometers
Dynamometer
PC
Fig. 7. Use of sensors for chatter recognition.
detection and avoidance, called Machining Navi. This application
can be implemented in the company machine tools through the
use of a microphone connected to a USB port or a piezoelectric
accelerometer integrated in the machine tool spindle. The soft-
ware is fully integrated in the NC screen and suggests improved
parameters for stable cuts, ensuring that the operator can auto-
matically modify them online. The use of microphones for
capturing and analysing the cutting sound has been demonstrated
to be an efficient and cheap solution. Perhaps one of its draw-
backs is that the sound coming from other machines of the factory
can introduce noise to the signal. However, there are several
signal treatment techniques to filter the sound and extract the
correct information. On the other hand, accelerometers, for
example, are more expensive than microphones and can also be
affected by the vibrations coming from other machine tools
through the workshop floor.
Faassen et al. [124] propose detecting chatter online at its
onset, before it is completely developed. Early chatter detection
allows operators to interfere in the process and avoid chatter
occurrence. Faassen et al. claim that the method presented can be
applied using various sensors, but for practical reasons they
prefer accelerometers. Doppenberg et al. [125] used the detection
algorithm presented in [124] to suggest a chatter controller that
forces the machining process into a region of chatter-free opera-
tion by adjusting the spindle speed when the onset of chatter is
identified. Tansel et al. [126] propose the use of index-based
reasoning (IBR) for chatter detection and tool wear estimation
through the torque signal data of rotary dynamometers during
end milling operations. The IBR is a simple reasoner that classifies
the incoming signals with the help of a lookup table after the
most descriptive features are identified through pre-processing.
Tangjitsitcharoen and Moriwaki [127] and Tangjitsitcharoen
[128,129] proposes an in-process monitoring method of chip
formation and chatter for turning processes using power spec-
trum density (PSD). Kuljanic et al. [130,131] developed a multi-
sensor chatter detection system for application in industrial
conditions. First, they compared several sensors, such as rotating
dynamometers, accelerometers, acoustic emission and electrical
power sensors, to determine which signals are most sensitive to
Chatter freemiling operation
FFT (RMS)
0.007
0.006
Amplitude
0.005
0.004
0.003
0.002
0.001
1000 2000 3000 4000 5000 6000 7000 8000
Miling operation with chatter
FFT (RMS)
0.140
0.120
Amplitude
0.100
0.080
0.060
0.040
0.020
2000 4000 6000 8000 10000 12000 14000 16000
 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
chatter onset. Suprock [132] and Suprock et al. [133] developed a
low cost wireless vibration sensor system for non-invasive inte-
gration into end milling tool holders. This device system can be
used among others to detect the onset of regenerative chatter.
Subrahmanya and Shin [134] propose a systematic approach that
allows the development and deployment of an online process-
monitoring system based on several sensors and its application to
plunge grinding. The authors use different sensors to measure
acoustic emission, spindle power, and workpiece vibration sig-
nals. Vela-Martı́nez et al. [135] developed a method to monitor
and predict the emergence of chatter based on the rescaled range
(R/S) analysis, which provides a statistical measure of the varia-
bility of a time series. The method is validated experimentally
with acceleration signals. Later on, Vela et al. [136] considered
accelerometer signals to detect chatter instabilities under differ-
ent spindle speed and depth-of-cut ratio conditions using
detrended fluctuation analysis (DFA), adapted for the time-fre-
quency domain, to monitor the evolution of cutter tool dynamics.
The DFA offers an advantage over traditional spectral analysis: it
can deal with non-stationary, nonlinear data. The method pro-
posed can identify instability dominance in the machine vibra-
tions. Yao et al. [137] propose an online chatter detection and
identification method based on wavelet and support vector
machines. The method permits chatter identification before it is
fully developed, avoiding the harmful effects of the self-excited
vibration with an accuracy of 95%. Zhang et al. [138] propose a
hybrid approach for chatter monitoring based on the hidden
Markov model (HMM) and artificial neural networks (ANNs).
The hidden Markov model allows the temporal modelling of
features extracted from time varying signals, and the artificial
neural network integrates the inputs. Eppel et al. [139] intro-
duced an optical device for measuring and recording the vibra-
tions in milling processes. The apparatus discriminates between
stable cutting and chatter vibration.
The main drawback of online techniques is that they wait for
the problem to appear and then take action, so the damage to the
part and the machine tool components is already done. In
roughing operations it might not be a problem, but it is not a
good solution in finish milling. Also, additional equipment is
usually required for them to detect and take action, so they can
be expensive. These factors make the predictive analytical solu-
tions more interesting in comparison, although they also face
some problems.
One of the principal objectives of this research line is chatter
identification as soon as possible – when chatter just begins and
is not completely developed – with the aim of reducing all its
negative effects. It is important to obtain relevant and useful
signals and to find efficient signal processing algorithms. Sensor
assistance is indispensable in this technique. However, external
sensors (dynamometers, accelerometers, power sensors, etc.)
typically used for process monitoring and chatter identification
have to be placed in the machine structure, in a fixed place near
the process, in order to obtain reliable signals and diminish the
information dissipation. Also, the signal treatment and chatter
recognition algorithms usually work in parallel in a separate
computer, not on the NC screen. It seems that solutions should
be more integrated in the machine tool-operator environment.
5. Passive chatter avoidance
In contrast to those methods that aim to avoid chatter by
situating the machining process in the stable zone of the SLD, high
MMRs can be obtained using another research line whose the aim
is to enlarge the stable zone of the SLD by expanding the stability
frontier or simply changing the system behaviour. These methods
371
are based on improving the design of the machine tool to change
its performance against vibration or on the use of extra devices
that can absorb extra energy or disrupt the regenerative effect.
Examples of these are passive damping devices installed in
machine tool elements with lower rigidity: friction dampers,
mass dampers or tuned dampers. This research line is focused
on ensuring chatter-free operations by using passive strategies to
damp, reduce and control the phenomena.
Wang and Lee [140] propose changes in the dynamic behaviour
of the machine tool system by redesigning the weakest compo-
nent of the structure. They performed several cutting tests and the
analysis of the process vibration showed that the spindle was the
weakest component. Marui et al. [141] increased the damping
capacity of a cutting tool system with inner friction plates.
Semercigil and Chen [142] suggested a passive vibration controller
– an impact damper – to reduce the excessive vibrations of an
end-mill cutter. Kim et al. [143] introduced a mechanical damper
into a cylindrical hole in the centre of a standard end-milling
cutter to dissipate chatter energy in the form of friction. Miguélez
et al. [144] focus on the behaviour of boring bars with a passive
dynamic vibration absorber (DVA) for chatter suppression.
The use of a non-standard cutting tool, i.e. with variable pitch
and variable helix milling tools (shown in Fig. 8), has been
proposed to increase the stable limit depth of cut by disrupting
the regenerative effect [145–151]. Yusoff et al. [152] experimen-
tally evaluated role of tool geometry in-process damped milling
by considering different cutting tool edge radii, rake and relief
angles, and variable helix and pitch angles. The authors show that
variable helix/pitch angles can significantly increase process
damping performance; the cutting edge radius moderately
improves process damping performance; and rake and relief
angles present a smaller effect. However, in industrial environ-
ments, the use of these non-conventional tools is still not very
extensive. This can be explained by a lack of knowledge about
their existence and the providers of conventional tools outnum-
bering the providers of variable helix/pitch tools, reasons that do
not contribute to increase the offer of and demand for non-
conventional tools.
In industrial environments it is possible to find tools with
integrated dampening like the Sandviks Coromant’s CoroMill
390. Also, the dynamic behaviour of the spindle system can be
enhanced by reducing the tool overhang/diameter ratio, a very
common practise in workshops, or using monoblock tools, where
α α α α
α β γ δ
α β γ δ
Fig. 8. (a) Conventional cutting tools; (b) Variable pitch cutting tools; (c) Variable
helix cutting tools.
372 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
the shank and the tool holder are the same body [110]. The use of
passive techniques or methods for chatter avoidance, reduction or
suppression is, in great part, related with machine tool design,
and for this reason machine tool manufacturers do not produce
many publications about their core activities.
6. Active chatter elimination
Active systems for chatter elimination are distinguished from
the passive methods basically by their ability to monitor the
dynamic state of the machine tool system, diagnose a certain
occurrence and actively execute those decisions that change, if
necessary, the system to a more adequate situation. Active
vibration reduction systems are usually composed of monitoring,
diagnosis and execution elements. This strategy is becoming more
important thanks to advances in recent years in fields such as
computers, sensors and actuators. With these strategies the SLD is
actively expanded or, at least, modified. Implementing them
requires the use of certain elements capable of modulating the
quantity of work provided, absorbing or supplying energy.
Olgac and Hosek [23] present a practical approach to chatter
elimination based on root locus plot analysis and use a device – a
delayed resonator – for active vibration suppression. Dohner et al.
[153] took an active control approach to mitigate chatter actively
by expanding the stability lobes diagram. Chiou et al. [154]
propose an algorithm to control machining chatter by changing
the response function of the structure and its modal properties
using active electrostatic and piezoelectric spindle bearing sup-
port. Huyanan and Sims [155] investigated the active control of
workpiece-induced chatter, with an active electromagnetic proof-
mass actuator. Moradi et al. [156,157] applied tunable vibration
absorbers (TVA) as semi-active controllers to suppress chatter
vibrations in boring processes.
Another method for active chatter suppression is varying the
spindle speed to disrupt regenerative effects [158]. The concept is
similar to the use of variable pitch mills but spindle speed
variation (SSV) is more flexible. It is a well-known technique to
suppress regenerative machine tool vibrations, but it is usually
considered to be effective only for low spindle speeds. Fig. 9
graphically shows two types of spindle speed variation (in
contrast with constant spindle speed): triangular spindle speed
variation and sinusoidal spindle speed variation. Al-Regib et al.
rpm
vc
t using simultaneous double-sided milling. This technique solves
rpm
vmax
vmin
t
rpm
vmax
vmin
t strength of an applied magnetic field. Brecher et al. [174] present
Fig. 9. (a) Constant spindle speed; (b) Triangular spindle speed variation;
(c) Sinusoidal spindle speed variation, S3V (c).
[16] present a method for programming spindle speed variation
for chatter suppression. They propose a sinusoidal spindle speed
variation, S3V, to disrupt the regenerative effect. Zatarain et al.
[159] present a general theory for the analysis in frequency
domain of any speed variation strategy. Zhang et al. [160] present
a systematic stability analysis of SSV based on a machining
chatter model of a nonlinear delay differential equation, verify
the results with numerical simulations and experiments, and
propose a formula for selecting the SSV amplitude. Seguy et al.
[161] analysed the effect of SSV on the high-speed domain for
spindle speeds corresponding to the first flip (period doubling)
and to the first Hopf lobes, and show that period doubling chatter
can be effectively suppressed by SSV, although, the technique is
not effective for the quasi-periodic chatter above the Hopf lobe.
Stable and unstable tests in terms of amplitude vibration and
surface roughness degradation provided in [162] validate the
analysis. The continuous variation of rotation speeds provides a
means of avoiding chatter instability in different machining
processes. Bediaga et al. [163] developed a strategy that detects
chatter emergence and, in accordance with SLD, determine
whether to take the machine to a stable spindle speed or change
it to continuous spindle speed variation. Industrial implementa-
tion of the strategy, to detect chatter and run the diagnosis
algorithm, is carried out using a portable digital assistant (PDA).
But, in general, the practical application of S3V, is not simple
because frequency and amplitude variation of the spindle speed is
critical: in some cases it is not easy to select cutting parameters
within the working limits of the cutting tool and guarantee a
stable process. It seems that S3V is more suitable in flip bifurca-
tion chatter. In grinding, Barrenetxea et al. [164] present a model
based on practical applications to avoid chatter with continuous
workpiece speed variation.
Other researchers propose the use of active elements for
chatter suppression. Active damping devices inject energy into
the system in order to compensate the current vibrations pro-
duced in flexible machine tool elements. These devices can
deliver forces or displacements by computer controlled actuators
that have to be able to provide enough stroke or force to cover the
major range of machine tool structure modes. Ganguli et al.
[165–168] propose the use of an active damping system, based
on an accelerometer to measure the machine tool vibrations and
an electromagnetic proof-mass damper, also called an active mass
damper (AMD), to enhance the stability limits of the system.
Wang et al. [169] used a nonlinear tuned mass damper (TMD) for
chatter suppression in machining. The authors compare its
performance with the common linear TMD showing that the
nonlinear damper can improve stability by suppressing the
magnitude of the real part of the FRF of the damped system.
Shamoto et al. [170] present a method to machine flexible plates
the difficulties of flexible plate milling but causes regenerative
chatter vibration. To suppress chatter, the authors propose rotat-
ing the two milling cutters at different speeds to cancel the
regenerative effects on both plate sides. Sathianarayana et al.
[171] studied chatter suppression with a magnetorheological
(MR) fluid damper in boring operations. The authors used FEM
for the design and optimisation of the MR fluid damper and then
fabricated and tested the damper to show that MR damper
application reduces the possibility of chatter and increases the
stability of boring processes. Mei et al. [172,173] developed a
magnetorheological (MR) fluid-controlled boring bar for chatter
suppression. The MR fluid can change stiffness by varying the
a chatter suppression approach based on the integration onto a
milling machine of an active workpiece holder with two high
dynamic axes controlled by piezoelectric actuators.
 G. Quintana, J. Ciurana / International Journal of Machine Tools & Manufacture 51 (2011) 363–376
7. Discussion
Due to its complexity, the chatter problem is still not com-
pletely solved. Further improvements should come with complete
understanding of the chip formation process. In coming years
models will become more sophisticated and accurate, including,
for instance, process damping, part behaviour, changes in struc-
ture or system dynamics along the tool path. A possible new
important focus of interest will study micro-machining processes
in depth. And advances in computers and sensors will undoubt-
edly play an important role in this field. Computers will increase
the calculation capacity and no simplifications will be assumed
due to computing time constraints. Sensors will obtain in-process
data to verify new models through experimentation. A useful idea
would be to identify the SLD of a given system composed of a
certain machine tool, tool holder, cutting tool and workpiece
material system in the primary stages of design and development
of new machine tools. This will be possible by applying techni-
ques such as finite element modelling. Then, it would be possible
to include these models in a CAM application and use the lobbing
effect to improve process parameters and tool paths before
starting the metal removal process.
When it comes to avoiding chatter in some complex processes
such as five- (or more) axes milling, it will be more useful and
efficient, also from an economic point of view, to use a monitoring
system to identify chatter as soon as it arises, before the vibration
is fully developed, and stop the process to modify, in-process or
out-of-process, the parameters and ensure a stable process. Of
course, changing the process parameters in-process is a better
solution, as stopping the process and redefining process para-
meters and tool paths is more time consuming and decreases
productivity. Improvements in sensors and signal processing
techniques will contribute to the development of this branch.
Control development will permit efficient online modifications of
the process parameters.
Due to the great variety of metal removal processes, machine
tool structures, configurations and capabilities, tool holders,
cutting tools and materials, etc., and observing the general trends
of the manufacturing sector, in the coming years advances will
result in more intelligent machines able to perform auto-diag-
nosis of incidences in order to evaluate cutting process efficiency
and to make decisions adapting the current cutting parameters to
increase productivity while ensuring quality parameters. With
this application, it will be possible to expand the actual manu-
facturing frontier and improve quality, productivity and economy,
the principal demands of the manufacturing sector.
8. Conclusions
Vibrations in machining result from the lack of dynamic
stiffness of some component of the machine tool-tool holder-
cutting tool-workpiece system. They can be divided into free,
forced and self-excited vibrations. If the system is well balanced,
the second type of vibration is due to variable chip thickness and
the interrupted nature of the process. That means that they are
always present. Therefore, to prevent damage, the vibration level
must be controlled. The most common self-excited vibration is
regenerative chatter.
A great deal of research has been carried out on the chatter
problem since the late 1950s, when Tobias and Fishwick [5],
Tlusty and Polacek [51] and Merrit [58] presented the first
research results focused on this phenomenon. Lots of significant
advances have been made over the years. Advances in computers,
sensors and actuators have increased understanding of the
phenomena, and developed and improved strategies to solve the
373
problem. This paper reviews the great amount of literature
regarding the chatter problem and classifies several methods
developed to ensure stable cutting into those that take the most
of the lobbing effect, out-of-process or in-process, and those that,
passively or actively, modify the system behaviour. The next
paragraphs briefly summarise the principal research lines:
i) Out-of-process strategies are focused on predicting, estimat-
ing or identifying the SLD through machining process model-
ling and analytical-experimental methods.
ii) In-process strategies are focused on identifying or recognising
chatter through the use of several sensor technologies, pro-
cess monitoring and signal treatment.
iii) Passive strategies are focused on the use of passive elements,
devices, methodologies or techniques that change or modify
the system behaviour and improve its performance against
chatter.
iv) Active strategies are focused on the use of elements, strate-
gies, devices or actuators that actively modify the system
behaviour to suppress chatter as soon as it occurs.
The advantages of detecting, identifying, avoiding, preventing,
reducing, controlling or suppressing chatter are obvious from the
negative effects avoided: poor surface quality, unacceptable
inaccuracy, excessive noise and tool wear, machine tool damage,
reduced material removal rate (MRR), increased costs in terms of
time, materials and energy, environmental impact and costs of
recycling, reprocessing or dumping non-valid final parts to
recycling points.
Acknowledgements
The authors thank Proffessor Luis Norberto López de Lacalle
and Fran Campa, from the University of the Basque Country who
helped on understanding chatter in milling processes and moti-
vation to do research in this field and Mikel Zatarain and Jokin
Muñoa from Ideko IK4 Technological Centre for their support and
help on discussions about chatter. Finally authors thank Anna
Ymbern for her help on preparing the figures in this paper.
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