Chatter problems in micro- and macrocutting operations, existing models, and influential parameters—a review

Abstract

Chatter presents one of the main problems in quality of machined surfaces limiting tool life, productivity, and tolerances. Chatter in milling and turning operations has been extensively analyzed; however, drilling operations have been neglected due to the complexity of drilling tools and problems that develop in the modeling of the tool. In this paper, an overview of chatter vibrations and chatter suppression in drilling has been presented. Models such as torsional–axial model, bending model, and the combination of axial and bending models have been presented showing the different effects each considers. Influence of parameters such as drill geometry, chisel edge, drill flank, pilot hole, margin engagement, stick–slip interaction, gyroscopic effect, and rotary inertia effects has been incorporated into the various models. In addition, the problem of chatter analysis and suppression in micromachining processes has been investigated. The differences in macro- and micro-scale problems have been addressed giving an overview of the current research directions and future work for both areas. The paper presents experimental as well as simulation data with the comparison of the two for clear understanding of the complex problems of chatter in drilling operations.