Milling Chatter Analysis

Project Supervisor: By:

Dr. Pavan K. Kankar Prashant Singh(2014126)
Subhadeepta Sahoo(2014183)
 INTRODUCTION

 Milling is popular material removal method, where rotating cutter is used to machine the
work piece.

 In the process, milling cutter is fixed on the spindle which is rotating to remove the
material from the work piece which is usually fixed on the table and is provided linear
movement towards the tool.

 Milling is an effective process not only because it can remove the unnecessary part of
material effectively, but also because it can create almost all kind of complex surfaces
smoothly.
 What is Chatter?
 Chatter can be defined as a type of self-excited vibration whose origin lies inside the
machine-tool-work piece system.

 Chatter in a machine system occurs when one of the modes of vibration of the machine
tool- work piece system is excited initially by the cutting force.

 Chatter is characterized as an instability in machining process, producing unnecessary

vibration between the tool and the work piece which results in noise production and a poor
surface finish.

 Therefore, it is vital to identify and detect chatter to get a better overview of the
performance of the machine at both the design of machine and stages of production.
 EFFECTS OF CHATTER
 Chatter leads to many harmful effects on the work piece and machine system. They are:

• Poor surface finish

• Poor accuracy of dimension

• Unwanted noise

• Machine tool damage

• Dissipation of energy as waste

• Reduced MRR

• Disproportionate tool wear

• Increased cost in terms of production time

 VIBRATION MODEL OF TOOL AND
WORK PIECE SYSTEM

Tool

Work Piece

 Equations of motion of cutting tool and work piece in X and Y directions are given as
2
𝜔𝑥𝑡
2 2
 𝑥ሷ + 2𝜁𝑥𝑡 𝜔𝑥𝑡 𝑛 𝑥ሶ + 𝜔𝑥𝑡 𝑛𝑥 = 𝑛
𝐹 𝑡 𝑦ሷ + 2𝜁𝑦𝑡 𝜔𝑦𝑡 𝑛 𝑦ሶ + 𝜔𝑦𝑡 𝑛𝑦 =
𝑠𝑥 𝑡 𝑥
2
𝜔𝑦𝑡 𝑛
𝐹𝑦 (𝑡)
𝑠𝑦 𝑡
2
2 𝜔𝑥𝑡 2
 𝑥ሷ + 2𝜁𝑥𝑤 𝜔𝑥𝑤 𝑛 𝑥ሶ + 𝜔𝑥𝑤 𝑛𝑥 = 𝑛
𝐹 𝑡 𝑦ሷ + 2𝜁𝑦𝑤 𝜔𝑦𝑤 𝑛 𝑦ሶ + 𝜔𝑦𝑤 𝑛𝑦 =
𝑠𝑥 𝑤 𝑥
PROPOSED METHODOLOGY
Measured Signal in the machining process.

Signal Processing using WPT

Selection of packet of wavelet having chatter information and reconstruction of that

particular packet of wavelet.

Chatter information using Hilbert Huang Spectrum.

HHT on the selected signal.

 EXPERIMENTAL SETUP

 A 3-DOF OKUMA MB-46VAE-R vertical milling machine centre (Figure 4.1) with a
maximum spindle speed of 8000rpm was used as the testing platform to perform the
experiments. The table of the CNC machine moves in the Y direction, and the spindle
moves in the X and Z directions. A T490 LNMT 0804 PNR insert has been attached to an
insert holder of end milling tool and the assembly is mounted on the spindle of the CNC
machine. A carbide end mill cutter of diameter 20mm with 3 inserts was used as the cutting
tool. The material of the work piece used was mild steel (170mm×100mm×40mm) having
hardness of 76 BHN.
 Experimental Setup

Accelerometer

Fig. OKUMA MB-46VAE-R Vertical Fig. Positioning of Accelerometer on

Milling Machine the spindle and work piece
 Experimental Parameters
The measurements were recorded by OROS data acquisition system (DAQ) and
transmitted to PC for signal processing and storage of data (Figure 4.3). The
sampling frequency was set at 51.2kHz. The slotting operation was performed at
varying cutting depths and spindle rotation speeds using a constant chip load of
0.03mm/tooth. All the tests were performed without the use of coolants.

Serial No. Cutting depth( mm ) Spindle Speed ( rpm )

1. 0.5 1500
2. 1 1500
3. 1.25 1500
4. 1 2800
5. 1.5 2800
 Signal Analysis FFT
 The acceleration signal recorded is obtained from data acquisition software OROS, in the y
direction for a process which is stable indicating absence of chatter is shown. The spindle
rotational speed was 1500 rpm, and the feed was 0.03mm/tooth. The cutting depth for this
particular slot milling process was selected as 0.5mm.
 The amplitude of the signal before and after the engagement of cutting operation was found
out to be 0.5 ms-2 which indicated the value of magnitude of background vibration noise.
After the engagement of the cutting operation the magnitude of the signal increased up to 1
ms-2 with the maximum amplitude of 2 ms-2.
Start of tool End of tool
engagement engagement
 Fast Fourier Transform
 The FFT plot clearly indicated that the frequency peaks at the multiples of
tooth passing frequencies do exist, though the magnitude of the frequency
diminished in the forced vibrations. FFT of the vibration showed the frequency
peaks which are dominant near 1622 Hz and 1650 Hz, which was because of the spindle
rotation at 1500 rpm. The highest peaks obtained in the FFT of the free vibration signal
were obtained due to system’s dynamics i.e. work-piece-tool interaction.