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Views: 0 Author: Site Editor Publish Time: 2025-04-08 Origin: Site
MAXNOVO MACHINE Tips : If you have worked in the field of Metal working or CNC Machine Machining, you are likely to experience “Chatter Marks” on the machined workpieces surface. The Chatter Marks is irregular patterns or defect that appears on workpieces' surfaces after machining operation. Because the interaction between the cutting tools and the workpiece would cause deflection or chatter, which often lead to Chatter Marks Occur. Chatter in machining leads to significant productivity loss and has badly impact on workpiece quality, cutting tool performance and the lifespan of machine tools. It often causes the rejection of workpieces or components and can't produce premium quality machined surface. In this article, we try to explore how to reduce Chatter Marks in machining.
Table of Content
1. What is Chatter Marks
2. Why does Chatter Marks Occur
3. How to Reduce Chatter Marks in Machining
4. Conclusion
Chatter marks is one common problems during metal machining. General Speaking, the Chatter Marks is irregular surface defect or patterns that appears on workpieces during machining process such as Turning, Milling, Grinding and etc.
Chatter Marks occurs due to many factors, they mainly include Cutting Tools, Workpiece Conditions, Chuck Clamping Force, Machining Speed, Machine Rigidity, Feeding Rate, Cutting Depth and Machining Parameters.
During machining operations, both the cutting tool and workpiece are subjected to big loads, which leading to deflection or slight bending. When this deflection occurs repeatedly, they will cause vibrational resonance — manifesting as chatter marks on the machined surface.
Even the machine with high rigidity, Chatter Marks still can occur if the cutting tools' clamping force is not sufficient. Additionally, the distance between the tool holder and cutting point, and the direction of applied forces also critically influence vibration. The interaction between the cutting tools and the workpiece would cause deflection or chatter, which often lead to Chatter Marks Occur.
According to our practical experience, machining conditions play an important part in affect the load, which is a major factor in Chatter Marks occurrence.
Spindle Speed (RPM)
Improper Spindle Speed will cause chatter.
Cutting Tool
If the cutting tools is not enough sharp or overhang length is too long size will cause the Chatter. At the same time, the cutting tool's "Length, Thickness and Applied Load" also would increase the risk of Chatter Marks.
Cutting Depth
Too much Large Cutting Depth or Small Cutting Depth also may cause Chatter.
Feed Rate (mm/rev)
Too much Fast feed rates and Slow feed rates all can cause chatter.
Workpiece Material
If the workpiece is too hard material (such as titanium) or Thin-walled also may cause Chatter.
To reduce chatter marks, you could consider these following tips:
3.1. Enhance Rigidity and Stability
Machine Setup : Ensure the machine is well securely mounted on a stable ground foundation or vibration-dampening base.
Tool Holding : Minimize tool overhang and use rigid tool holders. To use Anti-vibration toolholders can dampen harmonics.
Workpiece Holding : Fix the workpiece must Securely clamp. For long or thin workpiece could add supports like steady rests to prevent deflection.
3.2. Optimize Machining Condition
Changing the machining conditions is the most straightforward way to eliminate chatter while maintaining the existing equipment setup.
Spindle Speed and Feeding Rate Adjustments :
Reduce spindle speed (RPM) to avoid resonant frequencies or increase it for lighter cuts (such as in turning machining). But to change the spindle speed needs to consider cycle time and chatter's severity.
Adjust Feed Rates :
Too high feed rate would cause deflection, while too low feed rate may allow rubbing. The suitable Feeding Rate is important.
Depth of Cut: Use lighter axial or radial depths to lower cutting forces. Balance with feed rate to maintain good load.
3.3. Cutting Tool Selection
Sharpness : Use sharp cutting tools to reduce forces. Replace or regrind worn cutting tools in time.
Geometry : Select cutting tools with appropriate rake angles and coatings.
Type : In milling operation, to use high-efficiency (HE) toolpaths or trochoidal milling for load distribution.
3.4. Lubrication
Ensure adequate lubrication oil so as to reduce friction and heat.
Chatter Marks may cause from various factors. You need to balance many conditions such as spindle speed, feed rate, cutting depth, cutting tools, workpiece, machine rigidity and etc. By systematically optimize these factors, chatter marks would be significantly reduced or eliminated in machining.
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