Amin, A. K. M. Nurul and Azhari, A. and Mahmud, Md. Asif
(2011)
Chatter suppression in end milling of Titanium alloy Ti6Al4V applying permanent magnet clamped adjacent to the workpiece.
In:
Advanced Machining Towards Improved Machinability of Difficult-to-Cut Materials.
IIUM Press, Kuala Lumpur, Malaysia, pp. 107-115.
ISBN 9789674181758
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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
workpiece. Nakagawa et al. [1] stated it is meant as a problem has emerged during the endmilling
of hardened steels. Campa et al. [2] described chatter as a dynamic problem at high
removal rate conditions. Chatter is undesirable due to its adverse effects on the product
quality, operation cost, machining accuracy, tool life, machine-tool bearings, and machinetool
life. It is also responsible for reducing output because if chatter cannot be controlled,
then metal removal rates have to be lowered to eliminate chatter. Hence chatter must be
avoided to improve the dimensional accuracy and surface quality of the product [3]. A
system having self-induced vibrations can be said to have a negative damping [4].
In addition, Quintana et al. [5] specified that chatter can be obviously predicted from the loud
noise and the poor surface integrity due to the chatter mark.The chatter phenomenon actually
can be suppressed by some of methods. Nakagawa [1] showed that an end-mill with different
helix angles could prevent generative chatter vibration at lower cutting speeds and was also
effective in suppressing chatter vibration at higher cutting speeds.
Chatter conventionally, is determined using Fast Fourier Transformation (FFT), determining
whether received voice signals from a sensor are high frequency signals. The analytical and
experimental identification of the chatter frequencies in milling processes and the frequency
diagram are attached to the stability charts of the mechanical models. Kim et al. [6] also
showed the chatter prediction method in this study. With the advancement of a chatter
monitoring, the conventional FFT (Fast Fourier Transform) method was generally used. But
it needs huge number of data for reliable monitoring of end-milling force. In this chapter a
new method of chatter control is introduced for suppression of chatter during end milling of
titanium alloy Ti6Al4V. The magnet is clamped together with the workpiece using the
machine vise. Since titanium alloys are non-magnetic in nature this method could be
employed. However, the strength of the magnetic field can’t be maintained uniform at all
machining locations on the workpiece.
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