35 Regenerative Chatter in Machine Tools Robert G. Landers

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University of Missouri at Rolla

35.1 Introduction .......................................................................... 35-1

35.2 Chatter in Turning Operations ............................................ 35-3

Example 1

35.3 Chatter in Face-Milling Operations .................................... 35-9

Example 2

35.4 Time-Domain Simulation .................................................. 35-14

Example 3 † Example 4

35.5 Chatter Detection ............................................................... 35-18

Example 5

35.6 Chatter Suppression ............................................................ 35-20

Spindle-Speed Selection † Example 6 † Feed and

Depth-of-Cut Selection † Spindle-Speed Variation †

Example 7

35.7 Case Study ........................................................................... 35-24

Summary

Regenerative chatter, a result of unstable interactions between machining forces and structural deflections, is a great

limitation in machining operations. This chapter describes the modeling, analysis, simulation, detection, and

control of regenerative chatter in machining operations, and, in particular, turning and face milling. An analytical

method is applied to calculate the limiting stable depth-of-cut and corresponding spindle speeds to generate stability

lobe diagrams. The method is applied to both turning and face-milling operations. Time-domain simulation is

described and applied to turning and face-milling operations. Methods for chatter detection are presented and

experimental results from a face-milling operation are given. Chatter suppression techniques, namely spindle-speed

selection, feed selection, depth-of-cut selection, and spindle-speed variation, are presented and two simulations of a

turning operation are used to illustrate the spindle-speed selection and spindle-speed variation techniques. Finally,

a case study of a face-milling operation is presented. The nomenclature used in the presentation is listed at the end

of the chapter.

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