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4/3/20141Let'schataboutChatterAreyouexcited!
Thiswineglassis!
4/3/20142Anexcitedpart!
ChatteraboutchatterWhatischatterChatterisaresonantorharmoniceventthatoccurswhenthemachine,thecuttingtoolorworkpiecevibrates.
Thinkofthemachine,thetoolandworkpieceasasystem.
Whenoneoftheabovevibrates,itcanexcitetheother.
4/3/20143MoreChatteraboutchatterTherearethreethingsthatcausechatter!
Freeortransientvibrations.
Forcedvibrations.
Self-excitedvibrations.
Chatteranimation4/3/20144Affectstheaccuracyofthemachiningoperation.
Lowersproductivity.
PoorsurfacefinishPoortoollife.
Shortensthelifeofthemachinetool.
Chattercostindustrymillionsofdollarsayear!
ChatteriscostlyTwokindsofchatterToolChatteryourmachineandtoolaredoingthevibratingwhichistransmittedtotheworkpiece.
WorkPieceChatterthewalloftheworkpieceisvibratingsuchasthinwalledtubingorbellshapedparts4/3/20145CuresCuresWorkPiecechatterWorkPieceChatterMayactuallybemoredifficulttosolvebecausecomponentlimitsoptions…Maximizethebeefintheworkpiecethroughtoolpathsdon'tmachineawaytoomuchmaterialtoosoonMachinelongpiecesinsectionsbyusingabarpullerorthesub-spindleUsealternatemachiningmethodssuchaspinchturning,simultaneousturning,boxturning4/3/20146WorkPiecechatterSimultaneousturningmethodWorkPiecechatter4axisalternativeturningmethod4/3/20147WorkPiecechatter5axisalternativeturningmethodWorkPiecechatterChangethefrequencyoftheworkpieceIncreaserigiditybysupportingthewallsDampeningtheworkpieceofillingwithmaterialslikewax,plasticsandmetalalloysofillingthevoidwithamixtureofVaselineandleadshotorubberbandsaroundoutsideofcomponenttoabsorbvibrationsoUsevacuumtypefixturesoPartfittingsoftjaws,3DprintedjawsandsupportsoSteadyandfollowingrest4/3/20148ToolchatterToolChatterMaximizerigidityReducetooloverhangIncreasecomponentstabilityToolingReducingDeflectionpreferablylessthan.
001"Avibrationisavariabledeflection,thus,nodefectionmeansnovibration.
Thatmeansnodeflection=novibration!
Choosethelargestpossiblediameterandtheshortestpossibleover-hangtominimizedeflection.
ToolchatterToolChatterTunableholders4/3/20149ToolchatterEccentricnecktypeholdersToolchatterRigidClampingHoldersWhenusedwithprecisioncollets,Holdsthetoolsbetter,withincreasedholdingpressureandminimizesrunout.
4/3/201410HoldersmakeadifferenceFourdifferenttypeholdersHoldersmakeadifferenceTheFourholdersresults4/3/201411ToolchatterAnti-chattercuttersDifferentamountofflutes,Variablerakeandunequalhelix.
ToolchatterReducethesizeofthenoseRadiusorCutterDiameter4/3/201412ToolchatterReducethewidthofcutorengagementToolchatterEdgePrepeffectsforce,torque,toollife,surfaceroughness,andaccuracy.
4/3/201413SpeedsandfeedsfindtheRPM"sweetspot"sometimesslower,butfastercanbetheanswerFeedhardertoincreasetheloadonthetoolAlternatingpassesatdifferentDOCandspeedsChangeRPMsovibrationpatternchangesSomemachinesnowhavevibrationcontrolChatterSpeedsandFeedsTheMachineClampingforce.
Bothinthechuckandinthedrawbar.
ThefoundationThelevelofthemachineMakesurelevelingscrewsallhaveequalloadonthemMakesurethetoolisoncenter!
Chatterfromthemachine4/3/201414Therearemanycausesofchatter!
Don'tbeafraidtostoptrying!
ClosingChatter