Machine Tool Vibrations

Machine tool:
(objective) to achieve desired part geometry
through controlled relative motion of work and
tool
the form, dimensional and finish accuracies of
the part depend on the accuracy of relative
orientation and relative motion between the work
and tool
(causes) inaccuracies in manufacture and
assembly of machine tool components, static
stiffness and dynamic rigidity of the machine tool

 (static) steady loads including dead weight

of machine tool sub-systems and constant
components of cutting force can cause
static deflection of workpiece, tool and
machine tool
though the point of application of load
varies with time, this is relatively slow and
causes inaccuracies varying along the
length of the part

 (dynamic) time varying forces are developed

during the cutting process, which may
produce rapidly varying deflections in the
tool-work system
this dynamic deflection (vibration) affects the
form, dimensional and finish accuracies and
also reduce the life of cutting tool and
machine tool
Thus the machine tool must be designed to
be statically and dynamically rigid.

Machine tool as an elastic system comprising of

mass, spring and damper.

Depending on the nature of the disturbance

(external force), machine tool vibrations can be
classified as:
Free or random vibration
Forced vibration
Self-excited vibration

Free (random) vibration

Caused by sudden (impulse) loading
Large force lasting only for a very short duration of
time
Or when the structure is statically deviated from the
equilibrium and released
The structure starts vibrating at a particular
frequency
Eg: tool encountering a hard spot or discontinuity in the work
while machining, shocks transmitted through foundation

Un-damped response

Under-damped response

Forced vibration
When an external exciting force is present, the
machine tool structure vibrates at a frequency
same as that of the exciting force.
Eg: Periodic forces set-up by imperfect bearings/imbalance
in rotating members, vibrations transmitted through
foundation, periodic forces set-up by the machining
process like intermittent cutting, discontinuous chip/BUE
formation

Self-induced vibration
Vibration caused, built up and sustained by the
interaction between the excitation system and
the vibratory system

 In machining, the cutting process is the

excitation system, which develops the
cutting force and causes the disturbance
(displacement) in the vibratory system
(machine tool).
The interaction/coupling between the
cutting process and the machine tool
alters the nature of the excitation system
The cutting force fluctuates, which in turn
affects the nature of the vibratory system

Cutting process
(Excitation system)
Time
dependent
displacement

Time
dependent
force
Machine tool
(Vibratory system)

 The coupling between the cutting process

and the vibratory system depends on the
mutual orientation of the cutting force and
the direction of relative motion between the
tool and the workpiece.
If the mutual orientation is altered, the
coupling also gets altered
Under certain conditions, the random
vibrations set up during the cutting process
may build up into a severe vibration, known
as chatter

Chatter in machining
Regenerative effect
Mode coupling effect
Variation in penetration rate, speed, rake
and clearance angles

Wave generation/cutting

Wave removal

Regenerative effect

Wave removal over wave cutting

Mode coupling effect

Mode coupling effect

Due to the elliptical movement of the tool
tip, the cutting force opposes the tool
movement in one half of the cycle and
assists it in the other half.
This may also lead to variation in
penetration rate and actual cutting speed

 It was demonstrated that during a milling

process chatter can arise at certain
combinations of axial depth of cut and
spindle speed.
As a function of these two cutting
parameters, the border between a stable
cut and unstable one (i.e. with chatter)
can be visualized in a chart called
stability lobes diagram (SLD).

 To identify the SLD, the system

behaviour must be predicted or
modelled
The transfer function of a multidegree-of-freedom system can
be identified by structural
dynamic tests.
The structure is excited with an
impact hammer instrumented
with
a
piezoelectric
force
transducer and the resulting
vibrations are measured with
displacement,
velocity
or
acceleration sensors

UnstableUnstable
region region

Stable region
Stable region

Velocity profiles