Investigation of Control Methods of Chatter Vibration Based on Analysis of End-Milling Chatter Mark

Abstract

Chatter vibration generated by coupling a work-piece, machine tools, and cutting tool is a serious problem for engineers. A regular pattern forms the machined surface when chatter vibration occurs. There must be a direct relationship between the relative displacement and machined surface. We propose a method for controlling chatter vibration of end-milling from a machined surface. Hammering tests were first carried out to determine the natural frequencies of machine tools and the tool system, which are likely to be the cause of vibration. We also propose a technique of applying reverse analysis to end-milling surfaces. The machined surface is assumed to include an essential index to easily control chatter vibration at the factory. We found that chatter vibration occurs near the frequency of the cutting tool, tool holder, and their coupling, not at the natural frequency, and the chatter vibration frequency can be calculated by analyzing the surface pattern and cutting conditions. Moreover, the proposed method was effective in analyzing chatter vibrations including more than two kinds of natural frequencies at the same time.