Chatter is known as the vibrations which can occur in a machine or on the workpiece. It can be either be fine or quite violent and generate a distinctive loud noise. Chatter can be detrimental to your tool life, surface finish and can also affect your component dimensionally, therefore it is best to eliminate any risk of chatter beforehand.
Chatter can feed on itself. A vibration in the tool leads to a wave in the work piece; constant vibration creates a steady series of these waves. Once the surface is chattered and your tool tries to take a 2nd pass over this surface, the tool will follow the waves and peaks and the chatter will intensify and become even worse!
Types of chatter
There are two main types of chatter to be aware of:
TOOL CHATTER – Your machine and tool are doing the vibration which is transmitted to your workpiece. A couple of examples may be:
Using multiple helix geometry end mills (e.g. V7 Plus, X-Speed Rougher, TItanox Power) offer higher feed rates, larger depth of cuts and help eliminate vibration due to the special flute technology which breaks the cuttings off and interrupts the harmonics.
Program refers to the computations made to determine the path, speed, feed, timings etc. of the tool, so can play a part in creating chatter in machining.
Ensuring the correct feeds and speeds are used alongside the correct depth of cut are crucial.
The direction the tool paths are programmed. Tool engagement will determine the surface finish. If the end mill is cutting with 20% of the tools diameter and comes to a corner and a change in direction, for a split second the tool engagement may be 40% and you will hear that chatter before you see it! Programming the job so the tool path is at a constant engagement will overcome any chatter problems.
If you are struggling with chatter or vibration in your set-up, just give our Technical Team a call who will be able to walk you through the steps you need to take to eliminate or reduce this.
We also offer on-site visits where our Technical Application Engineers will be able to help optimise your tooling setup and suggest cost-saving, productivity-increasing solutions.
Call 01924 869615 or email firstname.lastname@example.org today!