Modelling and prevention of chatter vibration of milling machines

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Computer Numerical Control (CNC) machines may experience unwanted chatter or a self-excited resonant vibration of tools/workpieces during the machining processes. If not properly controlled, the vibrations can lead to a poor surface finish on the workpiece, deteriorate the machining accuracy, reduce the life of tools and CNC machines or even damage the tools and machines. The chatter occurrence is strongly affected by the dynamic response of the machine and tools. The objective of this project is to develop a numerical model to characterize the relationship between the cut and spindle speed of CNC machines in order to map out stability lobe diagram. The model will be excited by regenerative, time-varying cutting forces from the interaction between tools and workpieces. The stability obtained by the model will be validated by the results of cutting tests conducted on the instrumented CNC milling machine. The success of this project will provide a novel tool to map the stability lobe diagram. The outcome of this project will enhance the industrial partner's market competitiveness and train two highly qualified personnel in the related field.