Chatter in Machining: Tutto quello che c'è da sapere
When machining the parts for manufacturing, you will come across a lot of vibration and chatter, which causes a lot of problems. When it comes to dealing with the issue of chatter in machining, there are some essential things about it that you must know.
The guide below features the different types of chatter and how you can avoid it. So, let's read on.
What is Chatter in Machining?
Chattering in machining is the vibration that occurs when the parts are being cut and drilled. This chatter is because of the imbalance between the workpiece and the tool. The vibration starts when the cutting tool and the workpiece are moving against each other. It causes the tool to have a cutting load on the part.
Chatter in machining takes place due to the lack of an appropriate design for manufacturing, which creates noise and a wavy texture on the surface of the parts. There are two forms of chatter, which are resonant vibration and non-resonant vibration.
Non-resonant vibration happens due to the tools being unequally worn and it is caused through the entire machining cycle because of the mechanical causes. Resonant vibration, on the other hand, happens at certain stages of the tool path like the concave corners during machining.
Types of Chatter in Machining
There are two types of chatters in machining, and these are given below.
Tool Chatter
Fresatura CNC cutters produce a lot of vibration when cutting, and they start by trimming the workpiece, which then transfers the vibration to the workpiece. Due to this, the tool and workpiece start to slip and cause chatter, which keeps on increasing.
Workpiece Chatter
The workpiece chatter mostly happens because the workpiece is not properly fixed on the machine’s work table. It creates vibration, and the thin wall of the workpiece starts to vibrate; this vibration is then transmitted to the cutting tool.
There are certain chatters that cannot be avoided, and if the vibration during machining is more than 100µm, the workpiece may have scratches.
How to Recognize Chatter Marks in Machining
The patterns of the chatter marks are present in the form of a wavy look, and there are some other characteristics through which chattering marks can be identified. Some of these are given below:
- Chatter marks have a uniform pattern, which helps distinguish them from other types of imperfections on the surface.
- The chatter marks are also oriented in the direction which is the same as the tool path or is perpendicular to it.
- These chatter marks have varying depths; sometimes, they are too shallow, and sometimes deep enough to impact the functionality of the part.
- The individual chatter marks have space. When the space is close, it indicates that there has been high-frequency vibration, whereas the wide spaces indicate low-frequency vibrations.
- There is evidence of burnishing on a surface between the chatter marks which indicates that the tool must have rubbed itself rather than cutting.
What Are the Effects of Chatter in Machining?
The chatter in machining has some consequences that must be considered, and these are as follows:
- Due to the consistent vibration, the tool's life is compromised. It causes a jarring effect which ends up making the cutting tool blunt and damages the quality of the surface of the parts that are cut using them.
- The chatter in machining causes vibrations, and the machine's life is also compromised; the machine wears out faster, and so do its parts like spindles.
- Chattering in machining impacts the appearance of the components and even impacts their tolerances when subjected to harsh situations. The surface of the components is poor and rough.
- The chattering of cutting tools during the CNC machining process causes reduced dimensional accuracy. The path then either becomes too long or too short or sometimes too loose or too tight.
How to Avoid or Reduce Chatter in Machining?
There are different ways to reduce chatter in machining, and some of these are as follows:
Optimize Machine Configuration
You can optimize the configuration of the spindle, which helps to reduce the chatter. The spindle speed is also sometimes a cause for it, and you can use advanced CAM software, which helps to vary the speed with consistency.
Ensure Appropriate Work Holding
The machine's tools, which are well-balanced, offer improved adjustment. There are multiple factors, like fixing and inaccurate positions, which cause the chattering in CNC machines. Hence, the tool holder should be rigid so that the quality of the surface of the parts is not affected.
Moreover, when using fixtures and jigs for clamping the parts, make sure that if the workpiece is thin do not clamp just one side. By clamping a single side of thinner parts, the chances of chattering are high.
Select the Right Cutting Tool
When the cutting tool selected is accurate, the vibrations during machining are reduced. Some tools vibrate a lot, and hence, it is important to consider the tool based on the coating, the geometry of the component, and the tool’s aspect ratio.
Setting and Maintenance of the CNC Machine
CNC machines should be installed on a concrete floor that doesn't have any deformation or cracks. The arrangement of the machine plays a vital role in chattering during the machining. If the floor is damaged, the flow and trembling may increase in the Lavorazione CNC. Hence, anchors should be used to adjust the machine.
DEK Helps Offer Effective Machining Solutions
The surface quality of the components is important as it affects the functionality and performance of parts in many cases. Hence, you can choose us at DEK; we offer high-quality parts manufactured without any chattering during machining. So, contact us and get the parts manufactured with precision and high tolerance.
Conclusione
The subject of chattering in machining is very sensitive because these marks have a lot of consequences for the parts that are manufactured. Hence, it is important to avoid them and improve the quality of the parts. As you have read the guide, you might now be in a position to understand everything about chattering and ways to avoid the chatter marks.
