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Chatter marks meaning

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What causes chatterin machining

Machining performance is often limited by chatter vibrations at the tool–workpiece interface. Chatter is a type of machining self-excited vibration which originates from the variation in cutting forces and the flexibility of the machine tool structure. It may result in severe damage to the machine spindle, cutting tool and the workpiece and/or diminish the accuracy and quality of the machined surface.

1) Change in forces needed to cut caused by differences in the material- Material characteristics (such as work hardening or microstructural differences) that result in variation in chip thickness.

How to reduce chatterin machining

The various frictional, geometric and material phenomena that occur in the chip formation process affect the occurrence of chatter vibration. Examples of these phenomena include type of friction, tool edge roundness, changes in rake angle and clearance angle. (M. Mahnama, M.R. Movahhedy, Prediction of machining chatter based on FEM simulation of chip formation under dynamic conditions, International Journal of Machine Tools & Manufacture 50 (2010) 611–620 )

High-temperature alloys. High-temperature alloys or superalloys are another challenge. They contain chromium for oxidation resistance and elements like aluminum ...

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Machining chatter is an inherently nonlinear phenomenon that is affected by many parameters such as cutting conditions, tool geometry e.g., nose radius and clearance angle and frictional conditions at the tool/workpiece interface.

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Still think it’s the material? Here’s the Metallurgist’s tip:  Look and see if you have changing build up edge conditions on the tool that exhibits chatter. If  the self excited chatter is due to material such as an unstable built up edge (BUE)  forming,  try increasing the RPMs / SFM. Spindle speeds that are too slow allow workpiece material to weld to the tool edge  (pressure weld) and build up.This creates higher forces until it sloughs off.  Then forces go back to normal, and build up again until…

Higher RPMs help to keep BUE stable and under control. And they allow you to run faster cycle times, contributing to profits.

How to reduce chatter on a lathe

If forced vibration is what you have, confirming the integrity of the machine tool and its power train is a critical first step. Reducing the feed per revolution is one way to determine if it is the variation in the cutting process that is forcing the vibration. Changing the SFM or RPM’s by at least 25% is also something to try it can be increased or decreased

14,5. 0.5709 ; 37/64. 0.5781 ; 15. 0.5906.

Chatteringmark

To eliminate the self excited chatter, you can decrease the length of the tool in the cut,  shorten the tool holder, or substitute more rigid tooling and support materials (For instance, a carbide boring bar deflects less and can make three or more times heavier a cut  than one made of HSS).

Reduce chatter After Effects

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Self Excited Chatter is induced by a change in the cutting forces themselves, and is where the chatter that may be caused by the material.  Self excited vibrations can be distinguished from forced vibrations in the machining system. Because self excited vibrations stop when the cutting does. Forced vibrations are not dependent on the cutting process, and so continue even when the tool is not in the cut. Self excited chatter can be caused by:

2) Machine vibrations such as out of balance motors,  spindles, gear or shaft irregularities, bad couplings or bearings, (Loose motor mounts and weakened or stretched) couplings;

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Types of chatterin machining

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