Experimental Investigation of Chatter in CNC Turning Using Different Shim Materials

Abstract

The most widely used machining operation in the manufacturing is the turning. Machining Vibration or chatter is one of saviour outcome of non-linear motion of cutting operation which has immense effect on tool wear and surface roughness. Chatter in machining will ultimately reducing the productivity of system because of involvement of post processing or finishing operation. The different methods for chatter reduction are categorized into two types, active and passive chatter control techniques. One of the passive chatter control techniques is proposed in this paper. The chatter is reduced by using different shim materials between insert and tool holder, which causes change in damping value of the cutting tool. The different shim materials used are carbide, aluminum and brass. The harmonic analysis is used for finding the damping ratio for different shim materials, and computational simulation has been performed with the corresponding Rayleigh damping coefficient. Experiments were conducted for gathering the acceleration data, which is helpful in generating different plots such as fast Fourier transformation (FFT) plot, Poincare plot and Orbit plot using MATLAB. The surface roughness was also measured. All these data are helpful in predicting chatter reduction. The experimental data will be useful for design of the cutting tool and operating condition by operators.