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 Time dependent dependent displacement 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 multi-
degree-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