Chatter Growth—Tests to Evaluate the Theory

Abstract

Tests were run on a 30-hp Mazak slant turn lathe machining Inconel 718 with a 883 grade tungsten carbide button insert. The purpose of the tests was to evaluate the regenerative chatter theory of reference 1 and the chatter sensor and adaptive control strategies it predicts. The cutting system’s mechanical response was measured by shaking it at constant force through the swept frequency range of 30 to 1000 Hz. From these tests and static stiffness tests, the system’s effective mass, damping, and stiffness were measured. Cutting force tests were run to measure the machining system’s cutting compliance. The results of the shake and cutting tests were substituted into the regenerative stability model to predict the machine’s chatter behavior. The theory was consistent with test observations.