Chip serration frequency-the primary cause of chatter during end milling operation

Patwari, Muhammed Anayet Ullah and Amin, A. K. M. Nurul and Faris, Waleed Fekry and Azhari, Marian and Farahain, S (2009) Chip serration frequency-the primary cause of chatter during end milling operation. In: International Conference on Advances in Materials & Processing Technology (AMPT 2009), 26-29 Oct., 2009, Kuala Lumpur.

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Abstract

Chatter is an unwanted but sometimes unavoidable phenomenon in machining. The term defines the self-excited violent relative dynamic motion between the cutting tool and work-piece. Chatter is undesirable due to its adverse effects on the product quality, operation cost, machining accuracy, tool life, machine-tool bearings, and machine-tool life. It is also responsible for reducing output. This paper includes the findings of an experimental study on instabilities of the chip formation process during end milling of Ti6Al4V alloy at different cutting conditions with two different two holders and its influencing factors on chatter formation. The instabilities of chip formation process are expressed as primary or secondary serrated frequency. The chip formed at different cutting conditions is analyzed and its frequency was calculated. It is observed that the primary serrated frequency is more prominent in end milling of Ti6Al4V alloy and its chip serration frequency has significant interaction effect with the with the prominent natural mode frequency of the system components. The vibration signals in frequency domain (FFT) have been analyzed to identify the chatter frequencies which have been compared with the chip serration frequencies in different cutting conditions for two different tool holders. It has been fairly concluded from the experimental findings that chatter is the outcome of resonance, in between the frequency of primary or secondary serrated frequency with the ‘prominent natural frequency’ modes of the system components.

Item Type:	Conference or Workshop Item (Full Paper)
Additional Information:	2872/17033
Uncontrolled Keywords:	chip serration frequency, prominent natural frequencies, resonance and chatter
Subjects:	T Technology > TS Manufactures
Kulliyyahs/Centres/Divisions/Institutes (Can select more than one option. Press CONTROL button):	Kulliyyah of Engineering > Department of Manufacturing and Materials Engineering Kulliyyah of Engineering > Department of Mechanical Engineering
Depositing User:	Dr. A.K.M. Nurul Amin
Date Deposited:	26 Jan 2012 16:54
Last Modified:	21 Feb 2012 23:01
URI:	http://irep.iium.edu.my/id/eprint/17033

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