• Sharulhazrin, M. S.
• Amin, A. K. M. Nurul
• Patwari, Anayet U.
• Hafizuddin, I.

Abstract

Chatter is a self-excited vibration that occurs during machining operations resulting from instability of the cutting process with system responses of the spindle-tool-chuck system. In metal cutting operation, surface finish of the machined parts is vital issue that most machinists are concern on. A particular emphasis is given to chatter formation study during end milling to proof that surface roughness or surface integrity of the machined parts is critically dependent on the stability of the whole system during machining operation. In this paper an effort towards determining the influence of chatter formation during end milling operation of medium carbon steel (S45C) specimen and surface roughness generated is proposed. A study on the stability lobes for the prediction of chatter formation was first conducted considering the effects of cutting parameters and tool cutter on the amplitude of chatter. Vibration data were recorded using on line vibration data monitoring system for different diameter of endmilling cutters at different cutting speeds and depths of cut. The stability lobes diagrams for the two tool cutters of different diameters were drawn based on cutting speed and depth of cut. Certain restrictions had been made during machining operation to eliminate the effect of tool wear and heat generated. The dependence of surface roughness generated on chatter amplitude is justified /explained through surface roughness analysis. The surface roughness analysis is obtained based on calculation of surface roughness (Ra) for both tool cutters at different cutting speeds. It

Topics

• impedance spectroscopy
• surface
• Carbon
• grinding
• milling
• steel