Advertisement

Chatter problems in micro- and macrocutting operations, existing models, and influential parameters—a review

  • Tamara Novakov
  • Mark James JacksonEmail author
ORIGINAL ARTICLE

Abstract

Chatter presents one of the main problems in quality of machined surfaces limiting tool life, productivity, and tolerances. Chatter in milling and turning operations has been extensively analyzed; however, drilling operations have been neglected due to the complexity of drilling tools and problems that develop in the modeling of the tool. In this paper, an overview of chatter vibrations and chatter suppression in drilling has been presented. Models such as torsional–axial model, bending model, and the combination of axial and bending models have been presented showing the different effects each considers. Influence of parameters such as drill geometry, chisel edge, drill flank, pilot hole, margin engagement, stick–slip interaction, gyroscopic effect, and rotary inertia effects has been incorporated into the various models. In addition, the problem of chatter analysis and suppression in micromachining processes has been investigated. The differences in macro- and micro-scale problems have been addressed giving an overview of the current research directions and future work for both areas. The paper presents experimental as well as simulation data with the comparison of the two for clear understanding of the complex problems of chatter in drilling operations.

Keywords

Review Chatter Modeling Drilling Microdrilling Macrodrilling 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Tobias SA (1965) Machine tool vibration. Wiley, New YorkGoogle Scholar
  2. 2.
    Koenigsberger F, Tlusty J (1970) Machine tool structures, vol. 1. Pergamon, New YorkGoogle Scholar
  3. 3.
    Bayly PV, Metzler SA, Schaut AJ, Keith AY (2001) Theory of torsional chatter in twist drills model stability and composition to test. J Manuf Sci Eng 123:552–561CrossRefGoogle Scholar
  4. 4.
    Minis I, Yanusheshevsky R (1993) A new theoretical approach for the prediction of chatter in milling. J Eng Ind 115:1–8Google Scholar
  5. 5.
    Altintas Y, Budak E (1995) Analytical prediction of stability lobes in milling. Ann CIRP 44(1):357–362CrossRefGoogle Scholar
  6. 6.
    Roukema JC, Altintas Y (2007) Generalized modeling of drilling vibrations. Part II: Chatter stability in frequency domain. Int J Mach Tools Manuf 47:1474–1485CrossRefGoogle Scholar
  7. 7.
    Roukema JC, Altintas Y (2007) Generalized modeling of drilling vibrations. Part I: time domain model of drilling kinematics, dynamics and hole formation. Int J Mach Tools Manuf 47:1455–1473CrossRefGoogle Scholar
  8. 8.
    Tarng YS, Li TC (1995) Adaptive pattern recognition of drilling chatter. J Mater Process Technol 48:247–253CrossRefGoogle Scholar
  9. 9.
    Kalmar T, Stepan G, Moon T (2001) Subcritical Hopf bifurcation in the delay equation model for machine tool vibrations. Nonlinear Dyn 26:121–142CrossRefzbMATHGoogle Scholar
  10. 10.
    Ema S, Fujii H, Marui E (1988) Whirling vibration in drilling. Part 3: vibration analysis in drilling workpiece with a pilot hole. J Eng Ind 110:315–321CrossRefGoogle Scholar
  11. 11.
    Fujii H, Marui E, Ema S (1986) Whirling vibrations in drilling. Part 1: cause of vibration and role of chisel edge. ASME J Eng Ind 108(3):157CrossRefGoogle Scholar
  12. 12.
    Fujii H, Marui E, Ema S (1986) Whirling vibration in drilling. Part 2: influence of drill geometries, particularly of the drill flank on the initiation of vibration. ASME J Eng Ind 108(3):163CrossRefGoogle Scholar
  13. 13.
    Bayly PV, Lamar MT, Calvert SG (2002) Low frequency regenerative vibration and the formation of lobed holes in drilling. J Manuf Sci Eng 124(2):275–285CrossRefGoogle Scholar
  14. 14.
    Bayly PV, Lamar MT, Calvert SG (2002) Low-frequency regenerative vibration and the formation of lobed holes in drilling. J Manuf Sci Eng 124:275–285CrossRefGoogle Scholar
  15. 15.
    Altintas Y, Weck M (2004) Chatter stability of metal cutting and grinding. CIRP Ann Manuf Technol 53(2):619–642CrossRefGoogle Scholar
  16. 16.
    Tlusty J (1986) The dynamics of high-speed milling. J Eng Ind 108:50–67Google Scholar
  17. 17.
    Stone E, Askari A (2002) Nonlinear models of chatter in drilling processes. Dyn Syst 17(1):65–85MathSciNetzbMATHCrossRefGoogle Scholar
  18. 18.
    Stone E, Campbell SA (2004) Stability and bifurcation analysis of a nonlinear DDE model for drilling. J Nonlinear Sci 14:27–57CrossRefMathSciNetzbMATHGoogle Scholar
  19. 19.
    Campbell SA, Stone E (2006) Analysis of chatter instability in a nonlinear model for drilling. J Comput Nonlinear Dynamics 1:294–306CrossRefGoogle Scholar
  20. 20.
    Dilley DN, Bayly PV, Schaut AJ (2005) Effects of the chisel edge on the chatter frequency in drilling. J Sound Vib 281:423–438CrossRefGoogle Scholar
  21. 21.
    Dilley DN, Stephenson DA, Bayly PV, Schaut AJ (2005) Frequency shift in drilling due to margin engagement. J Manuf Sci Eng 127:271–276CrossRefGoogle Scholar
  22. 22.
    Arvajeh T, Ismail F (2006) Machining stability in high-speed drilling—Part 1: modeling vibration stability in bending. Int J Mach Tools Manuf 46:1563–1572CrossRefGoogle Scholar
  23. 23.
    Ulsoy AG (1983) A lumped parameter model for the transverse vibration of the drill bits. Control of Manufacturing Processes and Robotic Systems: 15–25Google Scholar
  24. 24.
    Ema S, Fujii H, Marui E (1988) Chatter vibration in drilling. J Eng Ind 110:309–314CrossRefGoogle Scholar
  25. 25.
    Rincon, D.M., Coupled force and vibration modeling of drills with complex cross sectional geometries, in Department of Mechanical Engineering and Applied Mechanics. 1993, University of Michigan: Michigan.Google Scholar
  26. 26.
    Arvajeh T, Ismail F (2006) Machining stability in high speed drilling—Part 2: time domain simulation of a bending–torsional model and experimental validations. Int J Mach Tools Manuf 46:1573–1581CrossRefGoogle Scholar
  27. 27.
    Rincon DM, Usloy AJ (1994) Complex geometry, rotary inertia and gyroscopic moment effects on drill vibration. J Sound Vib 188:701–715CrossRefGoogle Scholar
  28. 28.
    Timoshenko S, Young DH, Weaver W (1974) Vibration problems in engineering. Wiley, New YorkGoogle Scholar
  29. 29.
    Altintas Y, Chan PK (1990) In-process detection and suppression of chatter in milling. Int J Mach Tools Manuf 32(3):329–347CrossRefGoogle Scholar
  30. 30.
    Inamura T, Sata T (1974) Stability analysis of cutting under varying spindle speed. Ann CIRP 23(1):119–120Google Scholar
  31. 31.
    Li CJ, Ulsoy AG, Endres WJ (2006) The effect of spindle speed variation of chatter suppression in rotating tool machining. Mater Sci Forum 505–507:859–864CrossRefGoogle Scholar
  32. 32.
    Radulescu R, Kapoor SG, DeVor RE (1997) An investigation of variable spindle speed face milling for tool–work structures with complex dynamics, Part 2: physical explanations. J Manuf Sci Eng 119:273–279CrossRefGoogle Scholar
  33. 33.
    Sastry S, Kapoor SG, DeVor RE (2000) Compensation of progressive radial run-out in face-milling by spindle speed variation. Int J Mach Tools Manuf 40:1121–1139CrossRefGoogle Scholar
  34. 34.
    Smith S, Tlusty J (1990) Update on high-speed milling dynamics. ASME J Eng Ind 112:142–149CrossRefGoogle Scholar
  35. 35.
    Smith S, Delio T (1992) Sensor-based chatter detection and avoidance by spindle speed selection. ASME J Dyn Syst Measure Control 114:486–492CrossRefGoogle Scholar
  36. 36.
    Takemura T, Kitamura T, Hoshi T (1974) Active suppression of chatter by programmed variation of spindle speed. Int J Jpn Soc Precis Eng 42(11):1049–1055Google Scholar
  37. 37.
    Tsao T, McCarthy MW, Kapoor SG (1992) A new approach to stability analysis of variable speed machining systems. Int J Mach Tools Manuf 33(6):791–808CrossRefGoogle Scholar
  38. 38.
    Smith S, Tlusty J (1993) Efficient simulation programs for chatter in milling. Ann CIRP 42(1):463–466CrossRefGoogle Scholar
  39. 39.
    Tarng YS, Li TC (1994) Detection and suppression of drilling chatter. J Dyn Syst Meas Control 116:729–734CrossRefGoogle Scholar
  40. 40.
    Tarng YS, Lee EC (1997) A critical investigation of the phase shift between the inner and outer modulation for the control of machine tool chatter. Int J Mach Tools Manuf 37(12):1661–1672CrossRefGoogle Scholar
  41. 41.
    Tarng YS, Lee EC (1997) A critical investigation of the phase shift between the inner and outer modulation for the control of machine tool chatter. Int J Mach Tools Manuf 37(12):1661–1672CrossRefGoogle Scholar
  42. 42.
    Park SS, Altintas Y, Movahhedy M (2003) Receptance coupling for end mills. Int J Mach Tools Manuf 43:889–896CrossRefGoogle Scholar
  43. 43.
    Cheng CH, Arakere N, Schmitz TL, Duncan GS (2005) An approach for micro end mill frequency response predictions. ASME Manufacturing Engineering Division MED 16(2):1139–1145Google Scholar
  44. 44.
    Mascardelli BA, Park SS, Freiheit T (2008) Substructure coupling of microend mills to aid in the suppression of chatter. J Manuf Sci Eng. 130(0110101-01101012).Google Scholar
  45. 45.
    Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46:313–332CrossRefGoogle Scholar
  46. 46.
    Kim B, Schmittdiel MC, Degertekin FL, Kurfess TR (2004) Scanning grating interferometer for MEMS metrology. J Manuf Sci Eng 126:807–812CrossRefGoogle Scholar
  47. 47.
    Vogler MP, Devor RE, Kapoor SG (2003) Microstructure-level force prediction model for micro-milling of multi-phase materials. J Manuf Sci Eng 125:202–209CrossRefGoogle Scholar
  48. 48.
    Weule H, Huntrup V, Tritschler H (2001) Microcutting of steel to meet new requirements in miniaturization. Ann CIRP 50:61–64CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Limited 2009

Authors and Affiliations

  1. 1.Center for Advanced ManufacturingPurdue UniversityWest LafayetteUSA

Personalised recommendations