MACHINING CHATTER AND Prof.Dr.

Erhan Budak
SUPPRESSION METHODS
 CONTENT

 Introduction to Chatter
 Chatter Type Vibrations and Modelling
 Mechine Tool Dynamics
 Chatter in Milling
 Stability Diagrams
 Applications
 Chatter in Turning
 Chatter in Drilling
 VIBRATIONS IN MACHINING OPERATIONS

1- Chatter Type Vibrations: 2- Forced Vibrations.

 Self excited
 Process related
 Regenerative
 Increasing amplitude
Problems:
-High cutting forces
-Bad surface finish
-Lower tool life
-Lower tool holder life
-Tool brekage
-Lower spindle life
 Harmonic milling forces
 Instant depth changes in turning
 Amplitude is constant
Problems:
-Bad surface finish
-Lower tool life
-Lower tool holder life
 VIBRATIONS IN MACHINING OPERATIONS

3- Vibrations due to the Machine Tool 4- Others

(not Chatter related)  Due to the weak floor
 Low dynamic rigidity  Due to the other M/C vibrations
 Due to a flexible component
 Due to the movement of center of gravity
 Due to the high cutting forces
 Due to the faulty component
 Control based
 Amplitude is constant

Problems: Problems:
-Bad surface finish -Bad surface finish
-Lower tool life -Lower tool life
-Lower M/C component life -Lower M/C component life
 DIFFERENCES OF CHATTER

 Applied force is due to the process itself, not external

 It appears due to instability in the process
 Vibration amplitude increases continuously
 Even the system is rigid, chatter may still appear.
EFFECTS OF CHATTER

Chatter Stable
 EFFECTS OF CHATTER ON TOOL LıFE

0.35 L110 V170 L110 V110 L110 V50

L135 V170 L135 V110 L135 V50
0.3
S
C 70
Flank wear (mm)

0.25 SC 60

Tool life (min)

0.2 50

40
0.15
30
0.1
20
0.05 10
0 0
0 10 20 30 40 50 0 0.01 0.02 0.03
Tim e (m in) Vibration Amplitude (mm)

Flank wear
 IMPORTANCE OF THE PREDICTION OF CHATTER

 Inevitable when machining thin-walled structures or using long and

slender cutting tools.
 It may appear in all machining operations due to the process
dynamics.
 It is hard to find the solution with trial and error.
 It cannot be solved by «Mechanical Insigth» since the problem is
dynamic.
 The best stable regions occur at high cutting speeds with high depths of cut.
 These stable regions have to be calculated accurately.
 Finding high spindle speeds with high depths of cut results in
lowering machining time and costs.
 STABILITY DIAGRAMS
HIGH SPEED MACHINING

5
Depth of cut - mm

CHATTER
4

0
STABLE
5000 7000 9000 11000 13000 15000 17000 19000
Spindle speed - rpm
CHATTER VIBRATIONS

1. Case(Stable )
10

amplitude
Vibration
5

0
0 20 40 60 80 100
-5

-10
Time (s)
2. Case(Marginally stable )
20

Amplitude
Vibration
10
0
-10 0 20 40 60 80 100
-20
Time (s)
3. Case(Chatter )
600

Amplitude
400

Vibration
200
0
-200 0 20 40 60 80 100
-400
-600
Time (s)
 CHATTER VIBRATIONS

Dynamic Cutting Forces

h:chip thickness
Dyn a m i c Ch i p Th i c k n ess

Regeneration
 CHATTER VIBRATIONS

Dynamic forces occur due to dynamic chip thickness variations.

 DYNAMIC CHIP THICKNESS

c : Chatter frequency (rad/sn)

 : period (one full revolution of part/tool)
c  2 k   k : number of full waves left on the surface
 : phase (or residual waves)
 BASIC STABILITY MODEL

Frequency Response Function 1 1

blim  
2 K f min  GR   1 
2K f  
 4 k 
2 k
blim 
Kf

k : Modal stiffness (N/m)

 : Damping ratio (%)
Kf : Cutting force coefficient (MPa)
 EXAMPLE

Kf, cutting force coefficient at feed direction

Al : 400 MPa
Low carbon steels: 800 MPa
High alloy steels: 1000 MPa
Titanium alloys: 700 MPa

 or c, damping ratio
tool holders or tools: changes between 1% (0.01) – 4% (0.04)

k, modal stiffness
Depends very much on the material and geometry.
Ex:
12 mm diameter carbide milling tool with overhang length of 75 : 1e7 N/m
12 mm diameter carbide milling tool with overhang length of 75 : 2.3e7 N/m

blim=2*1e4*0.01 / 1000 = 0.2 mm

 STABILITY DIAGRAMS
HIGH SPEED MACHINING
Stability lobes
Marginally
stable 6

5
CHATTER
Depth of cut - mm

1
Absolute
0
STABLE
stability limit
5000 7000 9000 11000 13000 15000 17000 19000
Spindle speed - rpm
 STABILITY LOBES

Favorable regions with stable high depth of cuts

Increasing cutting speed increases the area of stability lobes.
Lower cutting speeds decreases these areas.
The highest lobe can be obtained when the tooth passing
frequency equals to the natural frequency of the system.
Other lobes are obtained by dividing the tooth passing
frequency with integers
Tooth passing frequency= rotating frequency x number of teeth
Rotating frequency= n/60 (number of revolutions in one
second)
 STABILITY DIAGRAMS
MULTIPLE MODES

3,0  There may be multiple modes

that may cause chatter
2,5  Spindle, tool holder or tool
Depth of cut - mm

2,0  If the modal frequencies are

not close to each other,
1,5 individual stability lobes can
be calculated and merged.
1,0
 If the modes are closer to each
0,5 other then the total FRF can
be used to calculate stability
0,0 diagrams.
2000 7000 12000 17000 22000 27000
Spindle speed - rpm
 STABILITY DIAGRAMS IN APPLICATIONS

10
9
8  A selected depth of cut and
depth of cut - mm

spindle speed couple that

7
results in stable cut for a
6 mode may cause chatter for
5 another mode
4
 Measurement and prediction
3
is more important in these
2 complex cases
1
0
5000 10000 15000 20000 25000
spindle speed - rpm
 CNC MACHINE TOOL DYNAMICS

 Components
 Tool – tool holder – spindle assembly
 Components carrying axis
 Tables
 Machine bed
SPINDLE – TOOL HOLDER – TOOL ASSEMBLY

 Especially for high speed CNC

M/C spindle is one of the
flexible components.
 Bearings and shaft diameter effects
the dynamic rigidity
 Response may change over time

 Contact between the spindle

and tool holder may be the
weakest component

 Tool holding, tool goemetry

and material affect dynamics
at the tool tip
 MACHINE BED

Linear Guides

Bearings

Lead screw
SPINDLE LOAD BEARING COLUMN

 Connection type of the columns to

the machine body is as important
as the column geometry and
material for dynamic rigidity

 If the column overhang length

changes it affects rigidty
 Least flexible condition should be taken
into account

 The weakest component can be

found by modal testing
DESIGN EXAMPLES
DESIGN EXAMPLES
CHATTER IN MILLING
ANALYTICAL FORMULATION OF MILLING CHATTER

det I  ΛA 0G(ic )  0 Characteristic equation


1
2a0

a1  a12  4a0  Eigenvalue solution
Kesme Derinliği
a0  Gxx (i c )G yy (i c ) xx yy   xy yx 
a1   xx Gxx (i c )   yy G yy (i c ) 2ΛR   ΛR  
2

alim  1  
 
 
 xx 
1
cos 2  2 K r  K r sin 2  ex
 NK t 
  ΛI   
2  st

 xy   sin 2  2  K r cos 2 ex

1  İş mili Devri
2 st

 yx   sin 2  2  K r cos 2 
1 ex  cT    2k ;     2 ;
2 st
 ΛI  60
 yy   cos 2  2 K r  K r sin 2 ex
1    Tan  1

; n
2 st Λ
 R NT
 CALCULATION OF STABILITY DIAGRAM

INPUTS:
1. Frequency Response Function at tool tip
- All modes should be taken into account

2. Tool-Workpiece Couple Process Model

- Orthogonal database
- Cutting force coefficients

3. Cutting Parameters

4. Part geometry and process

 FRF MEASUREMENT AND MODAL ANALYSIS

FRF measurement

a. Accelerometer

b. Impact Hammer

c. DAQ Setup

d. Software
 TOOL-WORKPıECE PROCESS MODEL

 Obtained from cutting tests or orthogonal

transformations

 Dynamometer is needed in order to measure forces

 Test limits should be selected regarding the real

application

 If there is no possibility to collect data estimated

values may be used
 Force coefficients affect the depth not the spindle speeds of
the stability pockets.
 Example for steel: Kt=1500 MPa, Kr=800 MPa
 OBTAINING THE STABILITY LIMIT

a0  Gxx (i c )G yy (i c ) xx yy   xy yx 

2ΛR   ΛR  
2
a1   xx Gxx (i c )   yy G yy (i c )
alim  1  
 
 
NK t   ΛI  
   xx 
1
2
cos 2  2 K r  K r sin 2  ex

 st

 xy   sin 2  2  K r cos 2 ex

1 
2 st

 yx   sin 2  2  K r cos 2 ex

1 


1
2a0
a1  a12  4a0  2
1
st

 yy   cos 2  2 K r  K r sin 2 ex


2 st
EFFECT OF SPINDLE SPEED AND AXIAL DEPTH
ON THE STABILITY- 1
3.5

2.5
depth of cut - mm

1.5

0.5

0
0 2000 4000 6000 8000 10000 12000
spindle speed - rpm
EFFECT OF SPINDLE SPEED AND AXIAL DEPTH
ON THE STABILITY- 2

Process damping: Effective at low cutting speeds

PROCESS DAMPING
 EFFECT OF RADIAL DEPTH OF CUT

10

9
 Depth of cut does not
full immersion effect the position of the
8 stability lobes but the
half immersion
eksenel kesme derinliği - mm

7 stable depths.
6

5  The change is not linear

4

0
0 2000 4000 6000 8000 10000 12000
iş mili devri - dev/dak
 EFFECT OF WORKPIECE MATERıAL

10

9  If the chatter is not due to

steel a workpiece mode, the
8 aluminum stability pocket positions
axial depth of cut - mm

7 do not change with the

6 work material, but the
stable depths of cut do.
5

4
 The change is due to the
3 change in cutting force
2 coefficients.
1

0
0 2000 4000 6000 8000 10000 12000
spindle speed - rpm
 EFFECT OF NUMBER OF TEETH

4.5
 Number of teeth affect both
N=2 the position and the depths
4 N=4 of stability pockets
N=8
eksenel kesme derinliği - mm

3.5
 Increasing number of teeth
3 result in moving the stability
pockets to lower cutting
2.5 speeds.
2
 Increasing number of teeth
1.5
decreases the absolute
1 stability limit and stable
depth of cut inside the
0.5 stability pockets.
0
0 2000 4000 6000 8000 10000 12000
iş mili devri - dev/dak
 EFFECT OF TOOL LENGTH

•Same tool with different clamping lengths

• In some cases longer clamps may be beneficial. Ex: in this case if the max
spindle speed is limited, then the stability pockets can be moved to lower speeds.
 EFFECTS OF FEED RATE

 There is no direct effect

 Effects the cutting force coefficients, in general increasing feed rate
decreases Kf
 It effects FRF(Gxx, Gyy). Increasing feed rate may increase the
stifness and damping of contacts.

a0  Gxx (i c )G yy (i c ) xx yy   xy yx 

2ΛR   ΛR  
2
a1   xx Gxx (i c )   yy G yy (i c )

alim  1  
 
   xx 
1
cos 2  2 K r  K r sin 2  ex


NK t   ΛI   2  st

   xy   sin 2  2  K r cos 2 ex

1
2


 
st

 yx   sin 2  2  K r cos 2 
1 ex
1
 a1  a12  4a0 2 st

 yy   cos 2  2 K r  K r sin 2 ex

1 
2a0 2 st
 EFFECTS OF RUNOUT

 It does not have direct effect

 If run out is too high than due to the missed
tooth, phase angle changes which effects
stability.
 TOOL HOLDER TYPES

14
axial depth of cut - mm 12
shrink fit
hydraulic
10 collet chuck

8
6
4
2
0
6000 9000 12000 15000 18000 21000
spindle speed - rpm
 EFFECTS OF TOOL HOLDER

•Tool holders with same type but different

lengths

•Holders with same length but different diameters

• FRF and stability limit is changed due to the

change in mass
 EFFECTS OF TOOL RADIUS

30
axial depth of cut - mm tool diameter = 20 mm
25 tool diameter = 16 mm
tool diameter = 12 mm
20

15

10

0
6000 9000 12000 15000 18000
spindle speed - rpm
 SPINDLE CHANGE
BEFORE AND AFTER
 EFFECT OF MACHINE TOOL ON STABILITY

12
axial depth of cut - mm

10

8
•Stability diagrams of
6 4 same model CNC’s
and merged single
4
stability diagram.
2

0
6000 9000 12000 15000 18000 21000 24000
spindle speed - rpm
STABILITY AND SPINDLE POWER AND TORQUE

Stability region cannot be used

due to limited torque
Torque curve of the spindle
STABILITY ANALYSIS BY SOUND MEASUREMENT
0.04

0.03

magnitue
axial depth of cut - mm 5 0.02

0.01
4
0
0 1000 2000 3000 4000 5000
3
frequency - Hz
Higher Frequency:
2
(1133+2833=3966Hz)
1
0.04

0 0.03

magnitue
9500 11500 13500 15500 17500 19500
0.02
spindle speed - rpm
model exp - chatter 0.01

exp - marginal exp - stable

0
0 1000 2000 3000 4000 5000
Natural frequencies of the system= Blue= tooth passing frequency frequency - Hz

1740 Hz, 2290 Hz, 2650 Hz Red= chatter frequency

 POSITIONS OF STABILITY POCKETS

60 f c
n (stable depth of cut cannot be calculated)
kN
fc, chatter frequency (Hz):
Frequenc y measurement is conducted during the operation.
If no measurement is done, natural frequenc y of the system can be selected.

N, number of teeth

k, pocket number to be calculated

Ex: Calculate the first 3 pockets of the stability diagram of a system having a natural freuency of 1000 Hz

60 x1000 60 x1000
n1 
60 x1000
 15000rpm n2   7500rpm n3   5000rpm
1x 4 2 x4 3x 4
 VARIABLE PITCH MILLING CUTTERS

 Used in order to change or eliminate

phase angle P0
 It can damp chatter
 Effective for both high and low cutting P0  P
speeds
 Pitch variations should be accurately
P0  2 P
calculated
 Specific tool is needed for each case
 Better to use at low or moderate cutting P0  3P
speeds
 Dynamic balance
VARIABLE PITCH AND VARIABLE HELIX CUTTERS
Optimum Pitch
 INCREASıNG STABıLıTY LıMıTS WıTH VARıABLE
PıTCH CUTTERS
Optimum P
10
s
P  
8 
c
6

r

4 P   for even N
vp
c
a 4-tooth
2 r lim
 ( N  1)
acr P   for odd N
c N
0
P0  ( P0  P)  ( P0  2P)  .....  [ P0  ( N  1)P]  2
0 0.25 0.5 0.75 1
 x2 2 ( N  1)P
P0  
1/4 1 13/2 N 2
INCREASING SURFACE QUALıTY WITH VARIABLE
PITCH CUTTERS

0.08
Sound Intensity (V))

420 Hz
0.06
300 rpm
0.04

0.02

0
0 300 600 900 1200
Frequency (Hz)

Optimal P=2o
Pitch=55,57,59,61,63,65
 LOWER CUTTING FORCES IN ROUGHING BY
CHATTER SUPPRESSION

•Reduce peak forces

5000 Equal Pitch Rougher •Increase tool life
Peak Force (N)

4000 •Higher feedrate

3000 0.06

Intensity (V)
0.04 367 Hz

Sound
2000
600 rpm
1000 Variable Pitch Rougher 0.02

0.00
0 0 150 300 450 600 750
Time Frequency (Hz)

P=48,52.8,57.6,62.4,67.2,72
CHATTER IN TURNING

For stability calculations

- 3D process geometry,
- Nose radius,
- Multi dimensional stability model
are used
 FLEXIBLE COMPONENTS IN TURNING

 In outer diameter (straight) turning the flexibility may come from both part and the
cutter.
STABILITY DIAGRAMS IN TURNING

60 f c
n N  1!!!
kN
60 *1000
n1   60000rpm
1
60 *1000
n2   30000rpm
2
60 *1000
n3   20000rpm
3
 EFFECTS OF THE NOSE RADIUS

Surface Roughness vs. Stability Limit?

EFFECTS OF NOSE RADIUS ON STABILITY IN STRAIGHT
TURNING OPERATIONS

Absolute stability limit - mm

0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0
0 0,4 0,8 1,2 1,6
Tool nose radius - mm
 EFFECTS OF NOSE RADIUS ON STABILITY IN
BORING OPERATIONS

1.2

1
Depth of cut (mm)

0.8

0.6

0.4

0.2

0
0 0.4 0.8 1.2 1.6
Insert nose radius (mm)
PRACTICAL SOLUTIONS FOR ELIMINATING CHATTER
IN TURNING OPERATIONS

1. Workpiece and cutter should be connected rigidly.

2. If the workpiece is more flexible then inserts having smaller nose
radius and approach angle should be used
3. If the tool is more flexible then inserts having bigger nose radius
and approach angle should be used
4. Tool with a damper can be used.
5. Depth of cut should be lowered.
6. Feed rate can be increased.
7. Cutting speed can be lowered (process damping)
8. Clearance angle can be lowered.
9. Hone radius can be increased
10. Stability limit calculations can be conducted.
 CHATTER IN DRILLING

 3 different vibration mode is effective

 Lateral vibrations (bending direction)
 Torsional and axial vibrations
 Whirling
 VıBRATIONS IN THE BENDING DIRECTION

 Change in chip thickness

CHATTER IN DRILLING

a. Stable
b. Torsional and axial vibrations
c. Whirling
d. Both torsional and axial vibrations,
and whirling
VIBRATIONS OF A TYPICAL DRILL
EXAMPLE EXPERIMENT - 1
EXAMPLE EXPERIMENT - 2

: stable
:torsion
x: bending
:torsion+bending
EXAMPLE EXPERIMENT - 3
 PROCESS DAMPING IN DRILLING

Chisel Edge has the most significant effect on process damping even though it increases
drilling forces and torque.