RobbJack Designed a Machine to Control Chatter
In a machining process, vibration results in chatter. Moreover, chatter occurs, while cutting tool and the work piece are vibrating at dissimilar frequencies and when, the work piece and the cutting tool are moving in opposite direction of each other. These relative movements are minor and occur at number of times per second. The chatter is the noise of the cutting tool and the workpiece bashing into one another at a high rate. The knocking is so irritating noise and it also harms the tool, damages the spindle, destroys the surface of workpiece and might leave behind part feature out of tolerance.
RobbJack, a cutting tool manufacturer has a strategy for dealing with the chatter, which based on the condition of making the tool and the workpiece to vibrate at the same frequency and at the same time. To this end, the company has developed a machine which can synchronize the vibrations of cutting tool and the workpiece during machining. This does not stops the vibrations but helps to stop the noise caused by out-of-sync vibrations.
Vice president of engineering at RobbJack, Mike MacArthur explained that the end mil design consists of a special edge preparation that makes an additional feature the mirror edge, as it is too shiny and highly polished. The added edge has tiny width, so it can hardly be separated by holding the tool and slight rotating it in the light.
Mr. MacArthur further added that this edge is enough to keep the flute in contact with the workpiece until another workpiece is engaged. This highly polished edge decreases frictional rubbing, so that it generates virtually no heat and does not change the workpiece surface. The continuous contact prevents the motion of the workpiece and the tool from going to wrong track. Thus the tool and the workpiece surface will keep moving in unison to maintain synchronization regardless to the frequency of the vibration. Neither the workpiece nor the tool will bounce away from each other and won’t gain different frequencies.
According to Mr. MacArthur, the tool need to be used with the flood or through the coolant to keep the chips away from interfering with the action of mirror edge. The tool does best with the aluminium, as the high spindle used for cutting this material tend to make higher cutting frequencies than that of created at lower frequencies.
This out-of-sync state can happen instantly, and as soon as it begins, the tool and the workpiece begin cutting off one another more accurately with each moving of the fluets among the workpiece.
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