Abstract
The general trend towards lightweight components and stronger but difficult to machine materials leads to a higher probability of vibrations in machining systems. Amongst them, chatter vibrations are an old enemy for machinists with the most dramatic cases resulting in machine-tool failure, accelerated tool wear and tool breakage or part rejection due to unacceptable surface finish. To avoid vibrations, process designers tend to command conservative parameters limiting productivity. Among the different machining processes, turning is responsible of a great amount of the chip volume removed worldwide. This paper reports some of the main efforts from the scientific literature to predict stability and to avoid chatter with special emphasis on turning systems. There are different techniques and approaches to reduce and to avoid chatter effects. The objective of the paper is to summarize the current state of research in this hot topic, particularly (1) the mechanistic, analytical, and numerical methods for stability prediction in turning; (2) the available techniques for chatter detection and control; (3) the main active and passive techniques.
Highlights
The study of chatter is closely related to the history of metal removal processes at the beginning of the 20th century
Chatter is a known problem in turning and it can be approached in many different ways
This review resumes some of the efforts in the state of the art to detect, avoid, and reduce chatter vibrations and its harmful effects
Summary
The study of chatter is closely related to the history of metal removal processes at the beginning of the 20th century. As early as 1907, Taylor, one of the fathers of modern machining, gives the first definition of chatter presenting this phenomenon as ‘perhaps the most obscure and difficult to ascertain’ [1] It was not until midcentury when its main causes were identified. When the tool/workpiece contact is not stiff enough, an oscillation is generated between them causing a distortion in the chip thickness parameter between two successive periods, t and t-T, where t is be the actual time and T the workpiece rotation period in the context of turning In this way, the process itself produces feedback causing a vibration whose frequency is near, but not exactly, to the natural frequency of the system. The authors identified the following items as possible sources of vibrations: (1) cutting tool (grain size, geometry, coating and wear and their effect on cutting forces) [4,5]; (2) workpiece material (type of material, homogeneity, hard grains, porosity, defects) [6,7];
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