Impact of Cutting

Vibration on
Machine Tools
MCTD (PE-208) MID-TERM PROJECT BY
- Dhruv Singhal (2K20/PE/25)
- Ayush Jain (2K20/PE/19)
 ABSTRACT
Vibration in metal cutting is familiar to every machine tool operator.
This phenomena is recognized in operations such as internal turning,
threading, grooving, milling, boring and drilling, to which there are
several reasons why this problem occurs. Some are related to the
machine tool itself, to the clamping of the tool, the length and diameter
of the tool holder and the cutting data to be used. More of this will be
discussed later

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 OUR
APPROACH
In a nutshell, vibrations in machining leads to a
substantial loss of productivity and may equally affect
the workpiece quality, performance and life of the
cutting tool and machine tool as well.
In our approach we will first discover the various
kinds of causes of vibrations and the inefficiency they
cause, then we will discuss the preventive measures of
this issue and how we can solve it. Took take our
research a step forward, we will have an industrial
visit where we will personally witness various
machines and interview the engineers there about
similar issues and what steps were taken to solve the
problem

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BACKGROUND
Machine tools play important roles in the metalworking sectors.
Machine tools vibrate more or less when in operation. Excessive
vibration may cause operational inefficiency, product-quality
problems, and increase the cost of manufacturing. Therefore,
predictions of cutting vibrations are important for reducing machine
downtime and work piece failure costs. In the past, predictions of
cutting vibrations were based on practical considerations, previous
experience and common sense.

Therefore, successful predictions of vibrations required staff with a

considerable degree of knowledge and experience. Although data
collection may be carried out by trained personnel, data processing
and an assessment of the state of the machine tools are the tasks of
engineers who have knowledge in various areas (design of machine
tools, mathematics, dynamic processing, and signal processing, etc.)
and who are able to apply this knowledge in this context.
BACKGROUND & NEED

“
Since machine tools have become more complex and
technologically sophisticated, traditional, prediction
methods have fallen behind. Research in the field of
advanced machine tools control, mainly focuses on
modelling, detection and the classification and planning
aspect of the disturbance. Not much research or
commercial systems tackle the prediction of the cutting
vibration before operation is commenced.

There will be several different actions to consider when

solving this problem. Reducing the process parameters
is one such consideration, however, this could have a
negative effect on productivity. Our focus, therefore,
will be easy hands on recommendations for productive
solutions and easy to use products.

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 What Are Maching Vibrations
Machining vibrations, also referred to as chatter, are forceful
vibrations that occur where a workpiece comes into contact
with a machine’s cutting tool. Both lathes and milling machines
have a cutting tool. It’s the single- or multi-bladed component
that presses against a workpiece. Machining vibrations occur at
the area where a machine’s cutting tool comes into contact with
a workpiece.

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 Effect Of Vibrations
In machine tools attempts should be made either to eliminate the
sources of vibration or to reduce them. To achieve this, it is
essential that first the effects of vibration on machine tools are
studied. The effects of vibrations can be considered on the
machine tool, work-piece, tool life and the cutting conditions.
For Example:
▫ Effect of vibrations on machine tool
▫ Effects of vibrations on work-piece
▫ Effect of vibrations on tool-life
▫ Effect of vibrations on cutting conditions
▫ Superficial Imperfections
▫ Machine Failure
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 ▪ Effects of Vibrations on Machine Tool
▫ The machine tool is made of various parts and when
vibrations are pro­duced, they also start vibrating at same
frequency. If this frequency approaches the natural frequency
of vibration of that part then amplitude of vibrations will be
very excessive and the part may break even.

▪ Effects of Vibrations on Work-Piece

▫ Due to pres­ence of vibrations the surface finish obtained will
be very poor and thus this aspect is very important for fine
finishing operations of grinding and boring etc. In such
machines the vibrations have to be completely eliminated.
Due to vibra­tions, the dimensional accuracy of the job is also
affected.

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 ▪ Effects of Vibrations on Tool-Life
▫ As the tool-life is a function of the cutting variables only, the
tool-life is greatly affected by presence of vibrations in machine
tools. It is found out that the tool life is decreased by about 70—
80% of the normal value if vibrations are present.

▪ Effects of Vibrations on Cutting Conditions

▫ By pres­ence of vibrations in machine tools, the chip thickness as
removed by the cutting tool does not remain constant and due to
it the cutting forces also vary. Also due to vibrations, vibratory
displacement of tool takes place in the direction of motion of the
job which results in the chatter of tool. The penetration rate also
varies and therefore penetration force does not remain constant.
Further due to vibration of the tool, cutting velocity does not
remain constant and it varies about the correct value.

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 Superficial Imperfections
Machining vibrations can lead to superficial imperfections in
workpieces. If vibrations persist during a machining operation
like turning, milling or drilling, the workpiece may develop
imperfections on its surface. These irregularities typically
consist of ridges and lines that aren’t found on other areas of
the workpiece. Rather, they are only found where the
workpiece was exposed to the cutting tool.

Superficial imperfections associated with machining vibrations

are so common, in fact, that there’s a name for them: chatter
marks. Chatter marks are the visible irregularities created on
the surface of a workpiece as a result of machining vibrations.
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 Machine Failure
Of course, excess vibrations can cause machines to fail
prematurely. Lathes and milling machines, as well as other
types of machines, often contain thousands of moving parts.
Over time, vibrations may cause some of these parts to loosen,
crack or otherwise degrade. If not addressed, the machine
could fail prematurely as a result of these vibrations.

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 Sources Of Vibrations
Vibrations in machine tools are mainly caused due to five
reasons:
i. Generation of vibrations from the cutting process (tool
chatter). These types of vibrations are self-induced and are
supplied from the cutting process under some particular
conditions.
ii. In homogeneities in the material being machined and
build up edges on the cutting tools. Due to sudden incre­
ment in hardness of tool or job, impulsive force is
generated which causes vibrations.

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 iii. Intermittent cutting as in milling. Due to it, forced
vibrations may be generated due to elastic nature of
system.
iv. Unbalance and disturbances in the drives caused due to
rotating unbalanced masses, faulty arrangement of drive
and fault in the supporting bearings.
v. Transmission from the ground which is vibrating due to
some other reasons. This can be minimised by isolat­ing
the machine tools from the ground.

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 How To Eliminate Or Reduce
Chattering
Different elements of the cutting process such as the cutting tool, toolholder, workpiece
and machine tool have a varying degree of stiffness which effect the dampening
characteristics exhibited during the cutting process. When such a structure is being
subjected to excessive cutting forces, it leads to dynamic instability of the cutting
process. For example, too slender of a tool or workpiece responds differently
to the same set of cutting conditions than their relatively beefy counterpart. Though
it maybe not always possible to eliminate chatter in machining, there are ways to
minimize it by addressing each element. Such as:
i. Work Holding
ii. Tool Holding
iii. Cutting Tool
iv. Isolation of Machine Tool Vibration

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 Work Holding
Workholding methods like fixtures, clamping tools etc. demand attention to
inhibit chatter. Their design should offer overall structural rigidity to
workpiece encompassing critical areas while supporting weaker part
features such as slender cross sections or thin bottoms. Fixture layout and
structure should consider the direction of probable cutting forces to provide
adequate damping as well as stiffness. Clamping should be robust enough
to deter micro movements generated due to excessive cutting forces. Once
you settle on a tool path, secure the workpiece as rigidly as possible. This
might be as simple as using a high-quality milling vise like the Kurt
DX6 outfitted with vise jaws, or gripping the workpiece with serrated teeth
vs. using smooth jaws or machining dovetails in the workpiece for extra
gripping force.

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 Cutting Tools
Cutting tools have a major influence in chattering, and in many cases, act as a
primary trigger point. As mentioned earlier, cutting tools are also one of the first
things that are altered when the vibrations begin, typically via a reduction in speeds
& feeds or by changing the tool outright. Therefore, the selection of the right tool
for a given application can never be emphasized enough. Some things to keep in
mind when choosing cutting tools are:
• Knowing when to use a solid carbide end mill vs. an indexable tool
• Using a serrated edge (knuckle) vs. a straight edge cutting tool
• For solid carbide tooling, using unequal spaced flutes and variable helixes
• For indexable tool, selecting an insert with smaller nose radius, sharper cutting
geometry, more positive rake angle, thinner PVD coated to even sharper
uncoated inserts or a combination of these tool features
• Choosing a tool with entering angle closer to 90° or lead angle closer to 0°
• For stationary applications, checking tool setup for incorrect center height
or lack of rigid clamping inside tool block also helps to eliminate chatter
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 Tool Holders
Toolholders, whether stationery or rotating, are a vital link between
cutting tool, workpiece and machine tool. Selecting a holder with a
shortest possible overhang and a largest possible diameter is proven
solution to minimize vibrations; even custom (i.e. tapered) tool design
also works out as an option where setup permits its use. For lathe
tools, most rigidity issues come from internal boring
applications. Toolholder materials affects static stiffness and damping
behavior during cutting. Steel bars works best for length to diameter
ratio up to 3:1 or max up to 4:1. When overhang lengths exceed this,
using high density material like heavy metal or carbide boring
bars deliver good results.

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 Isolation Of Machine Tool
Vibrations
Well-designed supports are essential to ensure that neither the
machine tool transmits vibrations through floor to other
machines, nor it receives vibrations/noise from other machine
tools. Thus to ensure smooth operation of a machine tool on
shop floor, resilient and well-designed supports need to be
provided to control transmission of vibration.
Computer aided designs have been developed to check
suitability of all types of mounting systems. Safe passing over
the resonance zone and ease of maintainability and replacement
are the unique features of all mountings.

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 Attempts need to be made to keep the natural frequency of the
isolator low enough as to control transmission of vibrations
over a wide range of operating frequencies. The
transmissibility of resonance can be kept to minimum by using
suitable type of damping material.
Further the vibrations can be isolated in a number of stages,
e.g., upper trough of isolator can be filled with concrete over
which a chequered plate can be embedded for proper sealing so
that concrete pack in absorbs vibration at the first stage.
Spring-damping material combination can reduce vibration in
the second stage, and low cast iron inverted trough can absorb
vibrations in the third stage.

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 Reduce Vibration In Turning
1. Choose a smaller nose radius than the depth of cut
2. Choose a positive insert with open chip breaker.
3. Increase the feed.
4. If there is between 4 x D to 6 x D overhang, choose a
carbide bar
5. If there is over 6 x D overhang, choose a Silent Tool.

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 Reduce Vibration In Grooving
1. Adjust the cutting speed (vc) as the frequency of vibration can
change and the vibration eventually can disappear.
2. Increase the feed slightly as this can reduce the friction created
when grooving and reduce the cutting action. However, this can
increase the deflection (the radial force).
3. Choose a thinner insert width and make several cuts, especially
for the finishing cut.
4. Check the clamping of the boring bar.

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 Reduce Vibration In Milling
1. For small milling cutters use if possible a tapered adaptor.
2. Try to balance the radial and axial cutting forces by using a smaller
entering angle. E.g 45 or 10 degree. Or maybe a round insert cutter.
3. Choose a milling cutter with a coarse tooth pitch and a positive design.
4. The width of cut should be approximately 75% of the milling cutter
diameter.
5. Positioning the milling cutter off-centre in relation to the workpiece
surface.
6. If possible choose a grade with thin coating and a sharp cutting edge.
7. Try to reduce cutting forces by using small corner radii and small
parallel flats.

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 Reduce Vibration in Boring
1. If possible, use a tapered adaptor to increase the static stiffness and
to reduce the deflection.
2. For long overhang, make sure to have a rigid clamping with flange
contact in the spindle.
3. Choose a small nose radius. For finish boring recommended nose
radius is 0.2 mm. Do not use larger nose radius than 0.4 mm. Try to
choose a nose radius which is smaller than the depth of cut.
4. Use sharp inserts with relatively thin coatings. Try an uncoated
insert. They will have a sharper cutting edge.
5. The entering angle should be close to 90 deg. This will give more
axial cutting forces and less radial/tangential forces.
6. Do not exceed half the cutting edge length when rough boring as
this will result in too high cutting forces on the cutting edge.
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 Industry Visit

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 THANKS!

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